Scalable intelligent power supply system and method

ABSTRACT

A scalable intelligent power-supply system and method capable of powering a defined load for a specified period of time is disclosed and claimed. Multiple external AC and DC inputs supply power to the system if available and required. An internal DC input from a back-up energy source is on board. The back-up energy source is scalable by adding additional energy cartridges such as batteries in racks mounted within frames of the system. The AC and DC inputs (including the internal DC input) are controlled, measured, sensed, and converted by circuitry controlled by the microprocessor into multiple AC and/or DC outputs. A microprocessor manages power input to, within, and output from the system. The performance of a Lithium-ion batteries used to power an automobile can be determined on the basis individual battery packs or individual battery cells within the packs. This enables the clusters or groups of Lithium ion batteries to be used in a vehicle such that these clusters operate and function as a “gas” tank or more appropriately as an “energy” tank.

This patent application claims priority of provisional application Ser.No. 60/771,771 filed Feb. 9, 2006 and provisional application Ser. No.60/781,959 filed Mar. 12, 2006. A related patent application was filedin the United States Patent and Trademark Office on Feb. 8, 2007 asserial no. 11672853. A related patent application was filed in theUnited States Patent and Trademark Office on Feb. 8, 2007 as serial no.11672957. A related PCT application was filed Feb. 9, 2007 asPCT/US07/61928.

FIELD OF THE INVENTION

The field of invention is in the field of intelligent power supplysystems having multiple alternating and direct current inputs andoutputs and rechargeable, interchangeable backup energy sources.Additionally, the invention is in the field of interchangeable batterypowered electric vehicle management systems which include rechargeable,swap-able and replaceable battery packs at electric vehicle refuelingstations.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 6,465,986 B1 issued Oct. 15, 2002 discloses batteryinterconnection networks electrically connected to one another toprovide a three-dimensional network of batteries. Each of theinterconnection networks comprises a battery interconnection networkhaving a plurality of individual component batteries configured withcompound series parallel connections. A plurality of rows of individualcomponent batteries are connected in parallel. A plurality of columns ofindividual component batteries are interconnected with the plurality ofrows with each column having a plurality of individual componentbatteries connected in series with an adjacent individual componentbattery in the same column and electrically connected in parallel withan adjacent individual component battery in the same row.

McDowell Research Corporation of Waco, Tex. produces a Briefcase PowerSystem for powering transceivers with an advertised DC input range of 11to 36 VDC and an AC input range of 95 to 270 VAC at 47 to 440 Hz. Nooutputs are specified in the advertisement at www.mcdowellresearch.com.

Automated Business Power, Inc. of Gaithersburg, Md. produces anUninterruptible Power Supply Transceiver Power Unit with advertised DCinput range of 9 to 36 VDC and AC input range of 85 to 270 VAC at 47 to440 Hz. Two outputs are specified both at 26.5 VDC, one at 5.25 A andone called auxiliary at 1A. Battery chemistry is not specified in theadvertisement at www.abpco.com, but indications are given thatnon-compatible battery types including primary Lithium battery(BA-5590/U), NiCd (BB-590/U), NiMH (BB-390A/U) or any othernon-compatible type shall not be useable.

There is a need for a light-weight intelligent energy system for use ina variety of applications including for use in energy supply systems forhomeland defense, military, industrial and residential use. There isalso a need for light-weight energy systems including battery systemsfor use in vehicles, cars, trucks, military vehicles and the like whichcan be refueled by swapping individual batteries or groups of batteriesat energy filling stations much like the typical gas stations.

SUMMARY OF THE INVENTION

The circuitry and control methodology described herein is applicable touse of modular energy supply systems in automobiles. For instance, thecontrol methodology described herein may be used in connection withLithium ion batteries used in an automobile. In this way, the batteriesmay be removed from the automobile and recharged at a service stationand then replaced into the vehicle fully charged. The batteries may beseparately removed from the automobile or they may be removed in groups.The invention as taught and described herein enables the evaluation ofindividual batteries and the evaluation of the energy remaining in thebatteries at the time they are swapped out (exchanged) for fully chargedbatteries. In this way a motorist can effectively refuel his or hervehicle and proceed on his or her way without worrying about stopping tocharge the batteries which is time consuming as the recharge time forLithium ion batteries is considerable. Having the ability to quicklyswap the batteries in a Lithium ion car enables the driver to get creditfor the energy in his “gas” tank. In reality the teachings of theinstant invention enable the driver to effectively have an “energy tank”as compared to a “gas tank.”

A power supply is disclosed which includes multiple alternating currentand direct current inputs and outputs. One of the inputs is a back-upenergy source which is carried on board within the power supply. Theback-up energy source may be batteries or fuel cells. An enclosure usedto house the power supply is expandable to include additional batteryracks each housed within an individual frame of the enclosure. A powersupply may also be expanded by interconnecting separate enclosures withthe use of appropriate cables.

The power supply is microprocessor controlled based on the status(voltage, current and temperature) of the inputs including the status ofthe back-up energy source, the status of converters and internal buses,and the status of the outputs. The microprocessor manages the back-upenergy source and the overall operation of the power supply byselectively coupling system inputs, buses and outputs. Where powersources are combined in an “or” relationship, diodes or theirequivalents are used to prohibit undesirable current flows. MOSFET basedswitches or their equivalents controlled by the microprocessor are usedextensively in the selective coupling of the system inputs, buses andoutputs.

The power supply disclosed herein resides in one or more weatherproofenclosures housing a battery rack having a plurality of batteries in atleast one frame portion. First and second fastening bars are affixed tothe frame portion. First and second connecting rods are attached to thefirst and second fastening bars and extend therefrom; the battery rackincludes a frame fastener and first and second fastening barsinterconnect with the frame fastener to secure the battery rack to theframe. A rearward portion of the frame includes an electricalmotherboard mounted thereon. A front door portion of the frame mayinclude one or more vents and fans.

Alternatively, the power supply is mounted in an enclosure whichincludes a plurality of frame portions connected to one another viarobust hinges and latches with weatherproof gasketing along the entireframe to frame interface surfaces. A plurality of battery racks residewithin the power supply with one rack residing in each frame and beingsecured thereto. Since the frames are hinged together they may beseparated from each other for maintenance. Additional frames may beadded to allow greater power levels or extended operating time or both.Likewise one or more frames may be removed if the power level oroperating time they represent becomes superfluous. Each rack includes aplurality of batteries in electrical communication with a motherboardwhich resides in the rearward-most portion of the plurality of frameportions hinged together. The front-most frame is a front door portionwhich includes vents and fans to cool the batteries and electronics ofthe power supply. Other relative positions of frame modules are possibleand anticipated. For instance, vents and fans may be positioned in therearward-most frame. The front-most frame may contain the motherboard.Alternatively, an intermediate frame may contain the motherboard andrearward-most and front-most frames could both contain fans and/orvents.

A process for servicing the embodiment of the power supply whichincludes a plurality of frame portions hinged together (with each framesecuring an arrayed rack of batteries) includes the steps of: unlockingthe latch side of a frame from the next adjacent frame; and, rotatingthe next adjacent frame about its hinged side to expose the frame to beserviced. The next adjacent frame may be the rearward-most frame whichincludes the motherboard for controlling each rack containing aplurality of arrayed batteries. The next adjacent frame may be any frameintermediate the rearward-most frame and the front-most frame. Eachframe may be separated from the next adjacent frame as the frames arehinged together. Removal of the hinge pin from the hinge may accomplishthe separation of the frames, or removal of fasteners retaining flangesassociated with the hinges to a frame may perform the separation, orother logical means of disconnecting framed, door-like, hinge connectedmodules from one another may be employed.

Alternatively, the above described frame portions may be separatelyenclosed and interconnected as required using appropriate weatherproofcable assemblies. A rack for housing a plurality of removable cartridgebatteries includes a plurality of shelves arranged in a stack typerelationship. The stack includes a bottom shelf and a top shelf.Intermediate shelves residing between the bottom shelf and the top shelfare vertically spaced apart from each other. The shelves include aplurality of bores therethrough with interconnecting rods extendingvertically through the bores in the shelves. A plurality of hollowspacing tubes (spacers) reside concentrically around the plurality ofinterconnecting rods and intermediate each of the shelves spacing themapart. Fasteners, such as nuts, are affixed to the interconnecting rodsbeneath the bottom shelf and above the top shelf. Other techniques ofconstruction are also contemplated wherein the spatial relationship ofthe shelves and overall ruggedness of the structure is maintainedcomparable to the above described connecting rod and spacing tubeconstruction technique. These other techniques may include formed sheetmetal components welded together or connected by fasteners to form asuperstructure into which the shelf elements may be placed and securelyretained by features of the engagement between the sheet metal and shelfelements (snap together construction) or by additional fasteners orother adhesive techniques.

Each of the removable cartridge type batteries includes a firstelectrical contact and a second electrical contact. The removablecartridge type batteries may be removable cordless tool batteries. Eachshelf contains one or more battery docking locations. Each dockinglocation includes a first electrical connector which matingly engagesthe first electrical contact of the battery and a second electricalconnector which matingly engages the second electrical contact. Firstand second wires are affixed to the first and second electricalconnectors and are routed to a battery interface circuit. Additionalcontacts and corresponding electrical contacts may be present uponbatteries and docking locations.

Alternatively, the shelves may include battery interface circuits in theform of printed circuits thereon. Each shelf includes a connector forcommunication with another board, typically a rack common board which inturn connects typically to the aforementioned motherboard. In thisexample the first and second connectors engage and are electricallyconnected to appropriate points of each respective printed circuit.

The power supply includes a programmable microprocessor for managinginputs, internal components and outputs based on continuously sampledand processed voltage, current and temperature measurements. Analternating current input source is selectively coupled to an AC/DCconverter which, in turn, is selectively coupled with an intermediate DCbus and/or a second DC bus and/or a third DC bus. First, second, andthird direct current input sources are selectively coupled with theintermediate DC bus and/or the first DC bus and/or the second DC busand/or the third DC bus. The intermediate DC bus is selectively coupledwith a first DC output and/or a DC/AC inverter and/or a third DC/DCconverter.

The third DC/DC converter is coupled to a second DC output and a thirdDC output. The first DC bus is coupled to a first DC/DC converter which,in turn, is selectively coupled to the intermediate DC bus and/or thethird DC bus and/or a DC charge bus.

The second DC bus is coupled to a second DC/DC converter which, in turn,is selectively coupled to the intermediate DC bus and/or the third DCbus and/or the DC charge bus.

The third DC bus is coupled to a fourth DC output and the third DC busis selectively coupled to a fourth DC/DC converter which, in turn, iscoupled to a fifth and sixth direct current output. The charge bus iscoupled to the third direct current input source. The third directcurrent input source is the battery back-up current source containingliterally almost any number of individual batteries. Batteries over awide range of inputs from 10 to 40 VDC will be used. However, it isspecifically envisioned that batteries over a wider range such as 1.5VDC up to hundreds of volts direct current may be used providedappropriate circuit element adaptations are made such as utilizingswitches rated for the voltage ranges being switched.

As previously stated, the power supply includes a microprocessor and thethird direct current input source includes a nearly limitless pluralityof removable cartridge battery packs. Each of the removable cartridgebattery packs is selectively connected or disconnected with a batterybus interconnected with a load. Each of the removable cartridge batterypacks is also selectively connected or disconnected with a charge bus.

One exemplary algorithm for operation of the plurality of batteries isas follows. The microprocessor selectively connects a first portion ofthe plurality of removable cartridge battery packs with the battery bus.The microprocessor selectively connects a second portion of theplurality of removable cartridge battery packs with the charge bus. Themicroprocessor selectively connects a third portion of the plurality ofremovable cartridge battery packs with both the battery bus and thecharge bus. The microprocessor selectively disconnects a fourth portionof the plurality of removable cartridge packs from both the charge busand the battery bus.

The first, second, third and fourth portions of the plurality ofremovable cartridge battery packs may include one, more than one, all,or none of the plurality of removable cartridge battery packs. Theplurality of removable cartridge battery packs may include batterieshaving different nominal voltages. “Nominal voltage” as used hereinmeans the voltage across a fully charged battery, namely, the opencircuit voltage.

One exemplary process for operating a power supply having a plurality ofbattery packs is disclosed and includes the steps of: monitoring thebattery bus output branch associated with each of the selected batterypacks and measuring the voltages thereon while supplying a load whichincludes a direct current to direct current step up converter;monitoring the battery bus output branch associated with each of theselected battery packs and measuring the voltages thereon whiledisconnected from the load; comparing the unloaded and loaded voltagesof each respective battery selected for operation and connection to theload; and, identifying battery packs to be charged depending on thecomparison of the unloaded and loaded voltages on each of the respectivebattery bus output branch(es). The process can also include the step ofcharging the identified battery packs. Still additionally, the processcan include the step of charging the identified battery packs at avoltage higher than the nominal voltage of each of the battery packs.

The battery back-up direct current input can be virtually limitless insize. Multiple frames can house multiple racks of back-up batteries. Theback-up batteries are expected to be in the range of 10 VDC to 40 VDC.Commercially available cordless tool batteries are in this range.Therefore, the power supply disclosed and claimed herein includes amicroprocessor and up to K batteries in parallel, where K is anypositive integer. I disclose battery arrays having 20 Li-Ion batteriesper rack. In the 20 battery per rack example each battery has a nominalunloaded voltage of 18 VDC. Each battery has a battery interface circuitwhich switchably interconnects each battery with up to N loads where Nis any positive integer. Each battery is switchably connected (throughthe battery interface circuit) with the charge bus. The back-upbatteries are connected in parallel and may be removed for use inanother application such as in another power supply or in a cordlesstool, other cordless appliance, vehicle, or other backup energyapplication. A monitor bus is also switchably interconnected by thebattery interface circuit of each battery and may monitor up to Kbatteries. Lastly, a sense resistor bus switchably interconnects with upto K batteries. The microprocessor directs power into and out of eachdescribed bus controlling up to K battery connections with up to N load,charge, monitor, and sense buses.

The microprocessor also prioritizes up to N loads and disconnects theloads in a prescribed order as to their relative importance atprescribed levels or remaining energy as remaining backup energydiminishes through periods of continuing operation.

Another embodiment of the power supply includes a plurality ofhot-swappable removable cartridge battery packs in parallelinterconnected with either a DC-AC inverter or with a DC-DC converterwhich in turn leads to the DC-AC inverter after the DC voltage isappropriately modified. Usually this modification will involve a step-upof the voltage. The DC-AC inverter provides an AC output. The removablecartridge battery packs are arranged in parallel with each other andinclude a common battery bus for communicating power to the DC-ACinverter. Each of the battery packs includes an output and a diode orequivalent circuit substituting the diode function arranged in serieswith the output of the battery pack communicating power to the commonbattery bus. It should be noted that alternative circuit implementationsare possible and contemplated.

The AC-DC input is fed to an AC-DC converter and then is ored togetherwith the output of the DC-DC converter. Alternatively, the output of theAC-DC converter could be ored together with the common battery bus if nomodification of the common battery bus DC voltage is desired.

The output of the AC-DC converter is interconnected in series with adiode and said common battery bus is interconnected in series with adiode and the diodes are interconnected in an oring fashion. In thisfashion the diodes or equivalent circuits protect the common battery busand/or the DC-DC converter and/or the AC-DC converter from back fedcurrent. The diodes are commonly joined in a bus which is interconnectedwith the DC-AC inverter.

The conceptual management hierarchy of the power supply system isdisclosed herein. Using this hierarchical arrangement the networkmanagement user may access the status and control parameters for allsubsystems under a particular gateway. Information is shown for thebatteries (energy subsystems and energy modules), inputs, converters,and outputs (power conversion and control units), and gateway. Allaspects of the underlying power supply status and operation may bemonitored and controlled by the user via this network. Up to P powerconversion and control units may be (where P is a positive integer)connected for management purposes to each gateway. Similarly, up to Senergy subsystems (where S is a positive integer) may be connected formanagement purposes to each power conversion and control unit. Up to Menergy modules (where M is a positive integer) may be connected formanagement purposes to each energy subsystem. Energy modules include butare not limited to lithium ion based batteries.

By virtue of this hierarchical arrangement the power supply user mayconfigure and control a power supply systems under a particular gateway.For example, one such physical arrangement may be a gateway unitconnected to at least one power conversion and control unit which inturn is connected to at least one energy subsystem which in turn isconnected to at least one energy module. As long as at least one energysubsystem having at least one energy module is connected to a powerconversion and control unit, the power conversion and control unit maycontinue to operate provide power and management control to the user.

It is an object of the invention to provide a power supply wherein atleast one input is a back-up energy source and wherein the back-upenergy source is rechargeable within the battery rack, is rechargeablewithin the rack but with the rack removed from the power supply, or isrechargeable when removed from the rack and from the power supply.

It is an object of the invention to provide a power supply wherein aback-up energy source includes a rack of individually controlled andrechargeable removable cartridge type energy packs.

It is an object of the invention to provide a power supply whereinremovable cartridge type energy packs are batteries.

It is an object of the invention to provide a power supply whereinremovable cartridge type energy packs are batteries at differentvoltages.

It is an object of the invention to provide a power supply capable ofreceiving I (where I is a positive integer) AC or DC inputs andcontrolling, measuring, sensing, charging and converting those inputs.

It is an object of the invention to provide a power supply capable ofsupplying Q (where Q is a positive integer) AC or DC outputs andcontrolling, measuring, and sensing, those outputs.

It is an object of the invention to provide a power supply capable ofmanaging I AC or DC inputs and managing Q AC or DC outputs byperiodically and continuously sampling and measuring system currents,voltages and temperatures.

It is an object of the invention to provide a power supply having I ACor DC inputs wherein at least one of those inputs is back-up energysource which may be a fuel cell rack, an atomic-powered generator rack,a Li-Ion battery rack, a NiMH battery rack, a NiCd battery rack, a leadacid battery rack, a Li-Ion polymer battery rack, or an Alkaline batteryrack. It is an object to provide a microprocessor controlled intelligentpower supply which effectively manages its backup power supply input.

It is an object of the present invention to provide a power supplyhaving a DC input from a plurality of removable, hot-swappable, andinterchangeable batteries which provide power on a common battery bus toa DC-AC inverter. Alternatively, and additionally, AC power may besupplied to the power supply through an AC-DC converter which is thenconverted back to AC for purposes of reliability and for the purpose ofseamless transition (uninterruptible power supply on-line topology). Theoutput of the DC to AC converter is arranged in a diode oring fashiontogether with the output from the common battery bus. The diode oringselects the higher voltage in converting from DC to AC power. Further,the common battery bus voltage may be converted by a DC to DC converterintermediate the common battery bus and the diode in series leading tothe junction with the output of the AC-DC converter. Use of the DC to DCconverter enables use of rechargeable batteries which have a relativelylow output voltage. It is an object of the invention, in this example,to provide a power supply which does not require a microprocessor tomanage its operations. Rather, this example provides a seamlesstransition from an AC power input to a DC power input withhot-swappability of the batteries. The batteries may be cordless toolbatteries capable of dual use. Further, the batteries may be Li-Ion orany of the types referred to herein.

It is an object of the invention to enable use of batteries in anelectric or hybrid automobile such that the batteries may beinterchanged and exchanged at a service station.

It is an object of the invention to enable the use of electric vehiclesby intelligently interchanging the batteries of the vehicles at aservice station.

It is an object of the invention to enable the use of electric batteriesin a vehicle such as a car wherein the electric batteries areinterchanged at a service station and credit is given for the energyleft in the batteries.

It is an object of the invention to enable use of electric vehiclesanywhere over long distances at high speeds without lengthy rechargeperiods as the batteries may be replaced at service stations just as agasoline powered car is fueled at a gasoline service station.

It is an object of the invention to enable electric vehicles havingbatteries arranged in series or parallel to be interchanged at a servicestation.

It is an object of the invention to enable continuous operation ofelectric vehicles indefinitely without taking the vehicle out of serviceto recharge the batteries on board.

These and other objects will be best understood when reference is madeto the following Brief Description Of The Drawings, Description of theInvention and Claims which follow hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of the intelligent power supplydevice illustrating a plurality of removable cartridge energy packs in arack.

FIG. 1A is a front perspective view of the intelligent power supplydevice similar to FIG. 1 without the removable cartridge energy packs inthe rack.

FIG. 1B is a front perspective view of the intelligent power supplydevice without the rack and without the removable cartridge energy packsin the rack.

FIG. 1C is a front perspective view of the rack illustrated in FIGS. 1and 1A.

FIG. 1D is a front view of the rack partially populated with theremovable cartridge energy packs in the rack.

FIG. 1E is a side view of the rack taken along the lines 1E-1E of FIG.1D.

FIG. 1F is a side view of the rack taken along the lines 1F-1F of FIG.1D.

FIG. 1G is an enlargement of a portion of FIG. 1D illustrating one ofthe removable cartridge energy packs in the rack.

FIG. 1H is an enlargement of a portion of FIG. 1F illustrating one ofthe removable cartridge energy packs in the rack.

FIG. 1I is an illustration of one of the shelves of the rack having thebattery interface circuits on and in the shelf underneath the batterycontacts/guides.

FIG. 1J is a perspective illustration of the removable cartridge energypack/battery pack illustrated in FIG. 1.

FIG. 1K is a front view of the removable cartridge energy pack/batterypack illustrated in FIG. 1.

FIG. 1L is a side view of the removable cartridge energy pack/batterypack illustrated in FIG. 1.

FIG. 1M is a perspective view of the removable cartridge energypack/battery pack rack removed from the frame of the intelligent powersupply device and stored in the door enabling maintenance on themotherboard in the rear of the device.

FIG. 1N is a perspective view of a modular intelligent power supplydevice indicating two frames each holding a removable cartridge energypack/battery rack, a front cover hinged to one frame and includingventilating fans and ports, and a rear cover hinged to another frame.

FIG. 2 is a front perspective view of the intelligent power supplydevice illustrating a plurality of other removable cartridge energypacks in a second rack.

FIG. 2A is a front perspective view of the intelligent power supplydevice similar to FIG. 2 without the plurality of the other removablecartridge energy packs in the second rack.

FIG. 2B is a front perspective view of the second rack illustrated inFIGS. 2 and 2A.

FIG. 2C is another front perspective view of the second rack illustratedin FIGS. 2 and 2A.

FIG. 2D is a front view of the second rack partially populated with theremovable cartridge energy packs in the second rack.

FIG. 2E is a side view of the second rack taken along the lines 2E-2E ofFIG. 2D.

FIG. 2F is a side view of the second rack taken along the lines 2F-2F ofFIG. 2D.

FIG. 2G is an enlargement of a portion of FIG. 2D illustrating one ofthe removable cartridge energy packs in the second rack.

FIG. 2H is an enlargement of a portion of FIG. 2F illustrating one ofthe removable cartridge energy packs in the second rack.

FIG. 2I is a perspective illustration of the removable cartridge energypack/battery pack illustrated in FIG. 2.

FIG. 2J is a front view of the removable cartridge energy pack/batterypack illustrated in FIG. 2.

FIG. 2K is a side view of the removable cartridge energy pack/batterypack illustrated in FIG. 2.

FIG. 2L is an example of a power supply which includes a three by threebattery array mounted in the rack along with receptacles and an on-offswitch.

FIG. 3 is a schematic for controlling, measuring, sensing, charging andconverting multiple inputs (energy sources) and multiple outputs (energyloads).

FIG. 4 is a schematic illustrating: an alternating current inputconverted to a direct current which is selectively switched tointerconnect with a direct current intermediate bus and/or a seconddirect current bus and/or a third direct current bus; the direct currentintermediate bus being selectively interconnected to a direct current toalternating current converter providing an alternating current outputand/or the direct current intermediate bus is selectively interconnectedto a first direct current output and/or the direct current intermediatebus is selectively interconnected to a third direct current to directcurrent converter to provide second and third direct current outputs.

FIG. 4A is a schematic illustrating a first direct current input, asecond direct current input and a third direct current input comprisinga removable cartridge energy pack rack direct current input, each ofwhich is independently selectively interconnected to the direct currentintermediate bus and/or the first direct current bus and/or the seconddirect current bus and/or the third direct current bus.

FIG. 4B is a schematic illustrating: the first direct current businterconnected with the input of a first direct current to directcurrent converter and the output of the first direct current to directcurrent converter is selectively connected to the direct currentintermediate bus and/or the third direct current bus and/or the directcurrent charge bus; the second direct current bus is interconnected withthe input of a second direct current to direct current converter and theoutput of the second direct current to direct current converter isselectively interconnected to the direct current intermediate bus and/orthe third direct current bus and/or the direct current charge bus.

FIG. 4C is a schematic illustrating the microprocessor, its power supplyand interfaces.

FIG. 5 is a schematic of one individual microprocessor-controlledinterface circuit; each individual interface circuit controls one of theremovable cartridge energy packs/battery packs and the selectiveinterconnection with the direct current energy pack/battery pack bus,the charge bus, the energy pack/battery pack monitor bus and/or theenergy pack/battery pack information bus.

FIG. 6 is a schematic illustration for obtaining load and removablecartridge energy pack/battery pack information for use by themicroprocessor with the load continuously connected to the removablecartridge energy pack/battery pack and with the load disconnected fromthe removable cartridge energy pack/battery pack.

FIG. 7 is a schematic illustrating up to K removable cartridge energypacks/battery packs selectively interconnected with N load buses, asense resistor bus, a charge bus and a monitor bus.

FIG. 8 is an illustration of the processing steps used in a configurablepower supply control algorithm implemented using a microcontroller.

FIG. 9A is a representation of intelligent power supplies connected tovarious loads (wireless routers and associated devices) for the twopurposes of supplying power to the loads and interfacing to a network.

FIG. 9B is a table illustrating computer monitoring and management ofthe scalable intelligent power supply management system.

FIG. 10 is a schematic of the 3.3V and 6.6V Power Supplies.

FIG. 11 is an example of a schematic similar to FIG. 5 of one individualmicroprocessor-controlled interface circuit for the control of one theremovable cartridge energy packs/battery packs and the selectiveinterconnection with the direct current energy pack/battery pack bus,the charge bus, the energy pack/battery pack monitor bus and/or theenergy pack/battery pack information bus.

FIG. 12 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 13 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 14 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 15 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 16 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 17 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 18 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 19 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 20 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 21 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 22 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 23 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 24 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 25 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 26 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 27 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 28 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 29 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 30 is an example of a schematic similar to FIG. 5 of anotherindividual microprocessor-controlled interface circuit.

FIG. 31 indicates an example of AC input and AC/DC converter circuits.

FIG. 32 is an example of an AC/DC converter and DC output voltage busconnection switch.

FIG. 33 is an example of First DC input circuits.

FIG. 34 illustrates an example of First DC input bus connectionsswitches.

FIG. 35 illustrates an example of Second DC input circuits.

FIG. 36 illustrates an example of Second DC input bus connectionsswitches.

FIG. 37 illustrates Third DC input battery pack array circuits.

FIG. 38 illustrates the Third DC input bus connection switches.

FIG. 39 illustrates an example of First DC/DC converter circuits.

FIG. 40 illustrates an example of First DC/DC converter bus connectionswitches.

FIG. 41 illustrates an example of Second DC/DC converter circuits.

FIG. 42 illustrates an example of First DC/DC converter bus connectionswitches.

FIG. 43 illustrates an example of DC/AC inverter circuits.

FIG. 44 illustrate an example of First DC output circuits.

FIG. 45 illustrates an example of Third DC bus and fourth DC/DCconverter circuits.

FIG. 46 illustrates an example of Fourth, Fifth, and Sixth DC outputsand Fourth DC/DC converter circuits.

FIG. 47 illustrates an example serial to parallel circuits to implementserial microprocessor control instructions into parallel controlsignals.

FIG. 48 illustrates an example of additional serial to parallel circuitsimplementing the microprocessor control signals.

FIG. 49 illustrates an example of additional serial to parallel circuitsimplementing the microprocessor control signals.

FIG. 50 illustrates an example of additional serial to parallel circuitsimplementing the microprocessor control signals.

FIG. 51 illustrates an example of Microcontroller interface circuits.

FIG. 52 illustrates an example of Microcontroller and support circuits.

FIG. 53 illustrates an example of Microcontroller interface circuits.

FIG. 54 illustrates an example of current monitoring circuits.

FIG. 55 illustrates an example of current monitoring circuits.

FIG. 56 illustrates an example of current monitoring circuits.

FIG. 57 illustrates an example of DC/DC converter voltage programmingcircuits.

FIG. 58 illustrates an example of Second and Third DC outputs and thirdDC/DC converter circuits.

FIG. 59A schematically illustrates twenty battery packs interconnectedin parallel to a common battery bus leading to either a DC-AC inverteror to a DC-DC converter which subsequently is interconnected to a DC-ACinverter.

FIG. 59B schematically illustrates the interconnection of the batteryarray with a DC-DC converter which is interconnected with a diode whichin turn is interconnected with a bus leading to a DC-AC inverter.

FIG. 59C schematically illustrates the interconnection of an AC inputwith an AC-DC converter which in interconnected with a diode which inturn is interconnected with a bus leading to the DC-AC inverter.

FIG. 59D pictorially illustrates the power supply with the battery rackremoved therefrom and the electronics (inverter, diodes etc.) mounted tothe rear wall of the housing or frame; also shown are two removableLithium Ion rechargeable battery packs.

FIG. 59E is a view similar to FIG. 59D illustrating the power supplywith the battery rack removed therefrom and further illustrating thepower receptacles, the AC input on the right hand side thereof, and theon-off switch.

FIG. 59F is a view similar to FIGS. 59D and 59E with the battery rackmounted in the housing or frame.

FIG. 59G is a view similar to the immediately preceding FIGS. 59D-59Finclusive with the battery rack populated with removable cartridge typeLithium Ion batteries and illustrating the power supply interconnectedwith a load such as wireless radio equipment.

FIG. 59H is a view similar to the immediately preceding FIGS. 59D-59Ginclusive with the door of the power supply closed and illustrating thepower supply interconnected with a load such as wireless radioequipment.

FIG. 60 is an illustration of the conceptual management hierarchy of thepower supply system.

FIG. 61A is an exemplary depiction of the physical arrangement of apower supply system.

FIG. 61B is an alternative depiction of a physical arrangement of apower supply system.

FIG. 62 illustrates a power supply using quick disconnect cartridge typebatteries for use in an automobile wherein the vehicles may be refueled.

A better understanding of the drawings will be had when reference ismade to the Description Of The Invention and Claims which followhereinbelow.

DESCRIPTION OF THE INVENTION

FIG. 3 is a schematic 300 for controlling, measuring, sensing, chargingand converting 302 multiple inputs (energy sources) 301 and multipleoutputs (energy loads) 303 with some of the energy routed back 304 forfurther processing by the controlling, sensing, charging, and convertingmodule 302.

FIG. 1 is a front perspective view 100 of the intelligent power supplydevice illustrating a plurality of removable cartridge energy packs 102in a rack residing in an enclosure 101. The rack is best viewed in FIGS.1C, 1D, 1E and 1F. Referring again to FIG. 1 the rack is not fullypopulated with batteries. The removable cartridge energy packs 102 arepreferably batteries and those shown are representative of a nominal 18VDC Li-Ion cordless tool battery manufactured and sold by Makita®.Makita® is believed to be a trademark of Makita Corporation of Anjo-shi,Aichi-ken, Japan. Any type of battery may be used but Li-ion (lithiumion), NiMH (Nickel Metal Hydride), NiCd (Nickel Cadmium), Li-ionpolymer, lead acid or alkaline batteries are presently contemplated.Li-Ion is one preferable choice because of its gravimetric (energy perunit mass/weight) and volumetric (energy per unit volume) efficiencies.

The United States Government (see 49 C.F.R. §173.185) and the UnitedNations (see 4th Edition of the Manual of Tests and Criteria) placesrestrictions upon the transportation of certain lithium and lithium-ionbatteries. Certain lithium-ion batteries having a smaller capacity andtherefore a lower lithium or equivalent lithium content are exemptedfrom these restrictions. This becomes an advantage of the intelligentpower supply design in that it preferentially incorporates these smallerlithium-ion removable cartridge batteries.

Referring, again to FIG. 1, a partially populated rack is illustrated todemonstrate that the power supply device will operate with at least oneback-up battery 102. The batteries 102 may be removed at any time evenwhile they are in operation and even while the power supply device is inoperation. This is known as being hot swappable. Reference numeral 110indicates a printed circuit board which contains 20 battery interfacecircuits thereon. FIG. 1C is a front perspective view 100C of the rackillustrated in FIGS. 1 and 1A and shows the back side of the printedbattery interface circuit board 110 attached to the shelves 103 of therack with screws 110A. Alternatively, the printed battery interfacecircuit board may be attached to the rack through the use of adhesivesor by interlocking aspects of the circuit board and the shelves or rackimplementing a “snap together” construction.

FIG. 1A is a front perspective view 100A of the power supply devicesimilar to FIG. 1 illustrating the power supply device without theremovable cartridge energy packs in the rack. It is anticipated that auser would wish to run the intelligent power supply device withoutpopulating the rack with batteries since in fact, as explained herein,the power supply device is functional provided an alternating currentsource and/or a direct current source is available. In this mode, thepower supply can serve to transform power sources on behalf of the user.For example, a 230 VAC 50 Hz input can be usefully transformed by theintelligent power supply into a 115 VAC 60 Hz output. See, FIGS. 4, 4A,4B and 4C. Still referring to FIG. 1A, printed circuit board traces areindicated by reference numeral 110B.

Referring to FIGS. 1 and 1A, shelves 103 are adapted to receive theMakita® 18 VDC Li-Ion batteries 102. Shelves 103 may be made of anelectrical insulator such as polycarbonate. Recesses 106 receive springloaded locks 111, 112. Reference is made to FIG. 1J, a perspectiveillustration 100J of the removable cartridge energy pack/battery pack102 manufactured by Makita® and which is illustrated in FIG. 1 et seq.FIG. 1K is a front view 100K of the removable cartridge energypack/battery pack 102 and FIG. 1L is a side view 100L of the removablecartridge energy pack/battery pack 102 illustrated in FIG. 1 et seq.Parts labeled 111, 112 are integral such that as button 111 is depresseddownwardly when viewing FIG. 1J against the force of an internal spring(not shown) tongue 112 recedes into the battery pack enabling insertionand withdrawal into the rack which is generally denoted by referencenumeral 100C. In this way tongue 112 engages the recess 106 of eachshelf 103 and securely positions the battery into place such that itcannot be removed even if the enclosure 101 is accidentally orpurposefully knocked over or subject to such shock and vibration as istypically present in vehicle, aircraft, vessel, or spacecraft bornapplications.

Still referring to FIGS. 1 and 1A, front door portion 107 is shown inthe open position exposing the interior of the enclosure 101 and theinterior of the door. Door 107 can be securely locked and padlocked toprotect the power supply device through known means. A threaded screw109 is illustrated as one way to secure the closure of the door.

Door 107 includes vents 117A which allow ventilation of the interior ofthe enclosure when door 107 is closed. Filters may be placed over vents117A to protect from the intrusion of unwanted dust, debris, insects orother foreign matters. Fans 117 located in the upper portion of the door107 expel warmer air from the device creating negative pressure thusdrawing cooler air in through vents 117A. Duct or baffling elements (notshown) can be included to the effect of directing cooler air enteringvia vents 117A first beneath battery rack lower shelf 103 wherefrom itflows upward across motherboard 120 (FIG. 1B) before traversing over topof the uppermost shelf and exiting via fans 117. In this way cooling ofpower conversion elements and other electronic and electrical elementshoused on motherboard 120 is efficiently accomplished. Operation of thefans 117 is controlled by the microprocessor 495 based on varioustemperature measurements. Wire harness 122A powers fans 117.

Still referring to FIGS. 1 and 1A, lip 118 is affixed to door 107 and isused to temporarily store the battery rack as illustrated in FIG. 1M.FIG. 1M a perspective view 100M of the removable cartridge energypack/battery pack rack removed from the frame 101 of the intelligentpower supply device and stored in the door 107 enabling maintenance onthe motherboard 120 in the rear of the device. Loop 118A is used inconjunction with one of the threaded interconnecting rods 104 to securethe rack in the door. Lip 118 secures another of the threadedinterconnecting rods 104. Door open sensor 108 interacts with block 108Aon door 107 to sense the position of the door. Door open sensor 108 isinterconnected to the microprocessor as indicated in FIG. 4C. In FIG. 4Cthe door open sensor is schematically illustrated using referencenumeral 491.

Still referring to FIG. 1, wires 139 are illustrated in conduit 138interconnecting with enclosure 101. Wires 139 include AC and DC inputsand outputs and communication lines. As previously indicated,microprocessor 495 is programmable over an Ethernet connection such thatonce the intelligent power supply is fixed, for example, to a pole orother bulwark and electrically connected to a network access elementsuch as a wireless access point via its Ethernet connection, it may bere-programmed periodically to carry out different algorithms oroperations depending upon the management systems' commands andrequirements.

FIG. 1B is a front perspective view 100B of the intelligent power supplydevice without the rack 100C and without the removable cartridge energypacks 102 in the rack. Motherboard 120 is illustrated schematically inFIG. 1B and includes, but is not limited to: input and output circuitry;the AC/DC converter; the DC/AC inverter; the first, second, third andfourth DC/DC converters; the first, second, third, intermediate andcharge DC buses; the microprocessor; interconnections between themicroprocessor and the voltage and current sensors on all inputs andoutputs; and, interconnections between the microprocessor andtemperature sensors located in proximity to the converters.

Referring to FIGS. 4, 4A, 4B and 4C, the microprocessor 495 makesvoltage measurements at all places indicated with a “V” having a circlearound it. Similarly, the microprocessor 495 makes current measurementsat all places indicated with an “I” having a circle around it.Similarly, the microprocessor 495 makes temperature measurements at allplaces indicated with a “T” having a circle around it. It will benoticed that the temperature measurements are not indicated as beingdirectly engaging any of the converters such as 406 and 414 for exampleillustrated in FIG. 4. Rather, these temperature measurements are madeby sensors on the motherboard in proximity to the device whosetemperature is being monitored. The sensors may be thermocouples,thermistors, platinum RTDs, semiconductors (temperature sensorintegrated circuits) or any other device which indicates a change intemperature as a function of voltage and/or current. Voltage, currentand temperature interfaces (460, 461 and 462) are interposed between themicroprocessor and the sensors. The microprocessor 495 may, for example,be a Texas Instruments mixed signal microcontroller capable of analog todigital conversion and digital to analog conversion and many otherfunctions. Many other microprocessors may be used instead of the TexasInstruments mixed signal microcontroller. An onboard and/or externaltimebase 463 will provide a realtime clock calendar so that time of dayand date is known and it will provide a high resolution clock so as tomake accurately timed measurements of system operation.

Referring to FIG. 1B, a fastening bar 124 is affixed to the enclosure101. Another fastening bar not shown resides above the motherboard 120.First and second connecting rods 125, 125A are affixed to the fasteningbar 124 and extend outwardly therefrom toward the front of the device.Nuts 126 are threaded and secured to the connecting rods 125, 125A toposition the rack (generally indicated as 110C) properly within theenclosure 110. Nuts 126 limit the rearward travel of the rack so thatthe rack does not engage or come too close to the motherboard.

Still referring to FIG. 1B, communication and power wire harness 122 isillustrated as extending from connector 121 to connector 123. Connector123 joins with connector 121A on the printed battery interface circuitboard 110. Alternatively, wire harness 122 may transmit power andcommunication signals with the individual shelves 103A having batteryinterface circuits thereon. See, FIG. 1I for the example of the batteryinterface circuits residing on the shelves 103A. Gasket 128 protects theinterior of the enclosure 101 from rain, snow, other forms of moisturesuch as salt and fresh water spray, dust, insects, and other foreign andpossibly degrading matter.

Referring to FIG. 1C shelves 103 having apertures 106 are shown in astacked relationship separated by hollow tube spacers 105. FIG. 1I is anillustration 100I of one of the shelves 103A of the rack having printedbattery interface circuits (140, 141, 142, 143) on and in the shelfunderneath the electrical contacts/guides 131, 132. Guides/electricalcontacts 131, 132 are “L”-shaped electrically conductive and metallicand are adapted to interfit with the Makita® battery packs 102.Referring to FIG. 1J slots 112A, 112B engage electrical contacts 131,132 and include battery contacts (not shown) which conduct energy to andfrom the battery 102. Referring to FIGS. 1D, 1G and 1F it will benoticed that the batteries 102 rest upon one of the shelves 103 and arespaced apart from the next adjacent shelf above the battery. FIG. 1G isan enlargement of a portion 100G of FIG. 1D illustrating one of theremovable cartridge energy packs 102 in the rack and illustrating thegap or space 150 between the battery and the shelf. A spring loaded lock112 is illustrated residing in aperture 106 of the shelf in FIGS. 1G and1H.

FIGS. 1D-1H illustrate the example wherein wires 149 are used totransmit power from the individual batteries (or other energy source) tothe respective battery interface circuit which is located on and inprinted circuit board 110 as illustrated in FIG. 1C, 1D and 1E. In theexample illustrated in FIGS. 1C-1F there are 20 battery interfacecircuits on printed circuit board 110. Another example (not shown)houses the 20 battery interface circuits directly upon motherboard 120with the individual battery connections made via wires from each batteryconnector location on each shelf to an appropriate connector associatedwith the battery interface circuit housed upon the motherboard. FIG. 5is a schematic 500 of one of the microprocessor-controlled interfacecircuits; each individual interface circuit controls one of theremovable cartridge energy packs/battery packs 102, 202 (see, FIG. 2)and the selective interconnection with the direct current energypack/battery pack bus 450A, the charge bus 489A, the energy pack/batterypack monitor bus 495A and the energy pack/battery pack information bus495B.

FIG. 1G is an enlargement of a portion 100G of FIG. 1D illustrating oneof the removable cartridge energy packs 102 in the rack. FIG. 1H is anenlargement of a portion 100H of FIG. 1F illustrating one of theremovable cartridge energy packs 102 in the rack. When reference is madeto FIGS. 1G and 1H, two of the wires referred to by reference numeral149 are viewed connected to threaded posts 131A and 132A by nuts 131Band 132B. The threaded posts and corresponding nuts also serve thefunction of securing the electrical contacts against the polycarbonateshelves. Posts 131A, 132A are viewed from above the shelves in FIG. 1Cand extend through the shelves and the guides/contacts 131, 132. It willalso be noticed from FIG. 1C that an additional screw (unnumbered) isthreaded into the guides/contacts to secure them to the polycarbonateshelf. FIGS. 1D and 1E illustrate the example where the temperaturesensor 133 is located in proximity to the battery 102 and a wire(s) areconnected to the sensor for communication with the battery interfacecircuit. All of the wires 149 are connected to connectors 151 on theprinted circuit board 110. Each shelf as viewed in FIG. 1E includes 4connectors for communication with the battery interface circuit.

FIG. 1I is an illustration 100I of one of the shelves 103A of the rackhaving the battery interface circuits on and in shelf underneath thebattery contacts/guides. In the example of FIG. 11, the shelves are madeof material suitable for the formation of printed circuits thereon, forexample, glass reinforced epoxy resin material. Vertically extendingconnecting rods 104 run through bores 148 in the shelves 103 and hollowtube spacers 105 separate the shelves from each other. Spacers 105 arestainless steel and sufficiently strong to support the shelves.

Still referring to FIG. 11, a representative temperature sensor 144which may be any of those referred to above is located intermediateelectrical contacts 131, 132 above the 18 VDC Makita® batteries. In thisexample the temperature sensor is part of the printed circuit boardwhich resides underneath the electrical contacts 131, 132. As statedpreviously, the Makita® battery 102 is a dual use battery wherein it mayalso be used in a cordless tool application. Other batteries includinguser-defined batteries may be used in a wide range of voltages andcapacities. Batteries can be charged on board the rack 110C within thepower supply or on a separate charger not associated with the powersupply device. Alternatively, an entire rack of batteries may be removedfrom the power supply device and connected to a special purpose externalcharger designed to charge any and all of the batteries in the rack.Battery power is supplied to bus 450A and reference numeral 147indicates system common. Temperature sensor information is communicatedusing a battery information bus 495B. A charge bus 489A isinterconnected with each battery information circuit (140, 141, 142,143) printed on the shelf 103A. Battery voltage information iscommunicated on battery monitoring bus 495A and battery controlinformation is communicated as represented by line 495Z. Referencenumeral 495Z represents several discrete control enable and disablechannels grouped together in combination. In the example of FIG. 11, aconnector will be employed to communicate with another printed circuiton board 110 which then communicates through connector 121A back to themotherboard. Alternatively, each shelf 103A may communicate directlyback to a connector on the motherboard as described above indescriptions pertaining to FIGS. 1D-1H.

Referring to FIGS. 1C, 1D, 1E and 1F, the top-most shelf 103 is held inplace against the spacer 105 beneath it by nut 138. Other fasteners maybe used to hold the shelves in place. FIG. 1D is a front view 100D ofthe rack partially populated with the removable cartridge energy packs102 in the rack. FIG. 1E is a side view 100E of the rack taken along thelines 1E-1E of FIG. 1D. FIG. 1F is a side view 100F of the rack takenalong the lines 1F-1F of FIG. 1D. Fastening bars 119 are secured abovethe top-most shelf 103 and fastening bars 129 are secured beneath thebottom-most shelf. Each of the fastening bars 119, 129 include bores119A, 129A therethrough for receiving rods 125, 125A which extend frombar 124 affixed to the enclosure 101. Additionally, fastening bars 119,129 include bores which allow vertical threaded interconnecting rods 104to pass therethrough. Nuts 138, 139 secure bars 119, 129 to the shelves.With bars 119, 129 secured to the rack and with interconnecting rods104/spacers 105 secured in place the rack functions as a stable andrigid unit. Bars 119, 129 includes bores 119A, 129A which allow passageof rods 125, 125A therethrough as well as other rods not shown butdescribed herein. Rods 125, 125A protrude from the end of bars 129 asillustrated in FIGS. 1 and 1A and nuts 127 are threaded onto rods 125,125A to secure the rack firmly in place within the enclosure 101.

FIG. 1N is a perspective view 100N a modular intelligent power supplydevice having two intermediate frames 152, 152A, each of which housesand holds a rack housing a plurality of removable cartridge energypacks/batteries. A front cover 153 is hinged 155 to the firstintermediate frame 152 and includes ventilating fans and ports. Thefirst intermediate frame 152 is hinged 154 to the second intermediateframe 152A. In turn, the second intermediate frame 152A is hinged 156 tothe rear cover 153A. Rear cover 163A includes a motherboard 160. Whenfully populated the modular intelligent power supply device of theexample of FIG. 1N provides twice the energy and power of the exampleillustrated in FIG. 1 fully populated.

FIG. 1N illustrates frame 152 being partially populated and employingshelves 103A having the battery interface circuits printed on theunderside thereof. Frame 152 may be partially populated because some ofthe batteries have been removed for use in other applications such as ona cordless tool. Or, the batteries may have been removed for use inanother power supply or they may have been removed to enable charging ona separate stand-alone charger. It will be noted that the modular powersupply device may be taken apart for maintenance by simply removing thehinge pin(s) holding the frame of interest. One major advantage of themodular design is that it enables servicing of the motherboard whilemaintaining (not interrupting) operation of the power supply system.

FIG. 2 is a front perspective view 200 of the intelligent power supplydevice illustrating a plurality of removable cartridge energy packs 202in a second rack. The other removable cartridge energy packs 202illustrated are 28 VDC Li-Ion batteries made by Milwaukee®, a registeredtrademark of Milwaukee Electric Tool Corporation of Brookfield, Wis. Theexamples of FIG. 1 and FIG. 2 provide approximately the same energy(nominally 1000 Watt-hours) and power (150 Watts) and weighapproximately 50 pounds. The example of FIG. 2 uses 12, 28 VDC Li-ionbatteries. The example of FIG. 1N will provide approximately twice theenergy (nominally 2000 Watts-hours). Different power levels may bepossible in any of the described configurations. A power level of 150Watts may be useful for powering lighter loads such as mobile wirelessrouters or wireless access points. A higher power level may be desirablefor various transmitter or transceiver communications gear, perhaps 300to 400 Watts. These and other power levels may be implemented via theuse of appropriately sized AC/DC, DC/DC, and DC/AC conversion unitswithin the intelligent power supply. Larger conversion units may requirelarger space within the power supply. Larger space may be achieved inthe modular approaches of FIGS. 1 or 1N by simply increasing the depthof the frame containing the motherboard or by increasing the width andheight of all frame elements or both. Larger conversion units and higherpower levels may also require larger fans and greater cooling capacity.Larger fans can be accommodated easily in any of the described designapproaches by increasing the depth of the fan and vent frame or byincreasing the width and height of all frames or both. In this way, avery wide range in the amount of backup energy and the power level ofthe supply can be achieved in appropriately scaled versions of theintelligent power supply.

Again referring to FIG. 1N, any number of intermediate frames may beadded to the modular power supply device to achieve the amount of backupenergy desired for a given application. In addition to the size of fansand vents being variable, the number of fans and vents may be increasedto improve cooling capacity as the number of intermediate frames isincreased as well. Power to operate the fans is provided by cabling asindicated by reference numeral 122A. Power supplied to and from thebattery racks housed in the intermediate frames is controlled by thebattery interface circuits associated with each battery and cable 122provides transmission of that power to and from the motherboard 160.Cable 122 also transmits control signals from the microprocessor to eachbattery interface circuit. In the example of FIG. 1N, fastening bars119, 129 are fastened to each of the intermediate frames by mounts 158or the like. Buckle type latches 157, 157A may be padlocked for securitypurposes to prevent the theft of the power supply device or itscomponents. The door open sensor 108 allows the microprocessor to beinformed if a door is opened. Using a network connection to a managementsystem the microprocessor can then inform the management entity with adoor open event alarm and can differentiate tampering versus bona fide,scheduled service so that management personnel can respondappropriately.

FIG. 2A is a front perspective view 200A of the intelligent power supplydevice similar to FIG. 2 without the plurality of the other removablecartridge energy packs in the second rack. Similar reference numeralswill be used in connection with describing the example of FIG. 2. FIG.2B is a front perspective view 200B of the second rack illustrated inFIGS. 2 and 2A. FIG. 2C is another front perspective view 200C of thesecond rack illustrated in FIGS. 2 and 2A.

Referring to FIG. 2, 28 VDC removable cartridge type batteries 202 areillustrated in a partially populated rack affixed within enclosure 201.As with the example of FIG. 1 input and output power and communicationwires 238 are illustrated entering through an electrical conduit 238.The structural arrangement of the rack as identified generally byreference numerals 200B, 200C is substantially the same as the exampleof FIG. 1 only modified to accommodate the physically larger batteries202. Referring to FIGS. 2B-2E, vertical connecting rods 204 pass throughbores in shelves 203. Spacers 205 reside over the vertical connectingrods 204 and support and separate the shelves 203 from each other.Spacers 205 have a diameter larger than the diameter of the bars in theshelves 203. Fastener bars 219, 229 include bores 219A, 229Atherethrough for interconnection with rods 225, 225A for affixing therack to the enclosure. Nuts 227 interengage the rods 225, 225A andsecure the rack to the enclosure 201. There are additional bores throughthe fastener bars 219, 219A for interconnection with the verticallyextending connecting rods 204. The fastener bars 219, 219A are mountedabove the top shelf and below the bottom shelf as illustrated. Rods 204are threaded and in conjunction with nuts 238 and 239 provide a secureand stable rack which can be handled without twisting and bending.

Door 207 operates to enable maintenance of the rack and the removal ofthe batteries 202. The rack can be stored over lip 218 by using loop218A to secure same and to enable maintenance on the motherboard. Fans217, power cable 222A, vents 217A, door open switch 208A, and block 208operates as was explained above in connection with similar componentsFIG. 1. Gasket 228 keeps unwanted rain and snow out of enclosure 201 andclosure means 209 lock the door 207 to the enclosure.

Referring to FIG. 2A et seq. printed battery interface circuit board210B is illustrated. Reference numeral 210 is used to generally indicatethe battery interface circuit and it will be apparent to those ofordinary skill in the art that the printed battery interface circuits(one for each battery) may reside on either the inboard side or theoutboard side of the board 210. Connector 221A and an unnumbered cableare used to transmit power and control signals between the batteryinterface circuits and the motherboard. Additional motherboardconnectors are used if additional racks of batteries in additionalframes are employed.

FIG. 2D is a front view 200D of the second rack partially populated withthe removable cartridge energy packs 202 in the second rack. FIG. 2E isa side view 200E of the second rack taken along the lines 2E-2E of FIG.2D. FIG. 2F is a side view 200F of the second rack taken along the lines2F-2F of FIG. 2D.

FIG. 2G is an enlargement of a portion 200G of FIG. 2D illustrating oneof the removable cartridge energy packs 202 in the second rack. FIG. 2His an enlargement of a portion 200H of FIG. 2F illustrating one of theremovable cartridge energy packs in the second rack. Battery 202interconnects with a Milwaukee® connector 231 and is spaced above theshelf 203 as indicated by the reference numeral 250. The Milwaukee® 28VDC battery 202 includes a locking mechanism 211 which coacts withconnector 231 to ensure that batteries are not unintentionally removedfrom the rack. The Milwaukee® connector includes two lips 230, 231 whichsupport battery 202 above the shelf 203. Connector 231 is secured to theunderside of shelf 203 with screws 231A, 232A as is best illustrated inFIGS. 2B and 2C.

FIG. 2I is a perspective illustration 200I of the removable cartridgeenergy pack/battery pack 202 illustrated in FIG. 2. FIG. 2I illustratesa groove 231B which coacts with the lips on the connector 231illustrated in FIG. 2G. FIG. 2J is a front view 200J of the removablecartridge energy pack/battery pack 202 illustrated in FIG. 2. FIG. 2K isa side view 200K of the removable cartridge energy pack/battery pack 202illustrated in FIG. 2.

FIG. 2L is an example 200L of a power supply which includes a three bythree battery array 257 mounted in the rack 256 enclosed in weatherproofcabinet 252 along with receptacles 255 and on-off switch 254 enclosed inweatherproof electrical box 253. Electronics are indicated withreference numeral 258.

In addition to the battery packs referenced above supplied by Makita®and Milwaukee®, other commercially available battery packs from otherapplication markets are anticipated and useable as backup energy sourceswithin the power supply. An example of such a battery pack would be theDigital DIONIC 160® power system offered by Anton Bauer, Inc. ofShelton, Conn. In any case, a shelf arrangement as depicted in FIG. 1and FIG. 2 for specific battery pack types would be further adapted toenable use of the Anton Bauer® or any other cartridge style energy pack.

FIG. 5 is a schematic 500 of one of the microprocessor-controlledbattery interface circuits. An interface circuit controls one of theremovable cartridge energy packs/battery packs 102, 202 and theselective interconnection with the direct current energy pack/batterypack bus 450A, the charge bus 489A, the energy pack/battery pack monitorbus 495A and the energy pack/battery pack information bus 495B.

Still referring to FIG. 5, the microprocessor 495 multiplexes voltagesignals from the battery monitor bus 495A and, as explained previously,is capable of converting analog to digital signals. The microprocessorenables 495E the voltage monitoring of each of K batteries in the systemaccording to clocked signals (i.e., the timebase 463, see, FIG. 4C). Thebattery monitor bus is isolated from the battery output/input 503 by twoN-channel MOSFETs 519, 520. The monitor enable 495E applies voltageacross resistor 527 to the gate of N-channel MOSFET 526 which, in turn,divides the battery voltage across resistor 525 in proportion to thecombined resistance of resistors 524 and 525 and applies that voltage tothe gate of P-channel MOSFET 521. P-channel MOSFET 521 then allowsconduction of current through resistors 522 and 523 dividing the voltageacross resistor 523 in proportion to the combined resistance ofresistors 522 and 523 and applies that voltage to the gate of N-channelMOSFETs 519, 520 enabling the voltage to be measured and sampled by themicroprocessor 495. One exemplary P-channel MOSFET which may be used isP channel Metal Oxide Semiconductor Field Effect Transistor (MOSFET)made by International Rectifier. One exemplary N-channel MOSFET whichmay be used is N-channel Metal Oxide Semiconductor Field EffectTransistor made by Vishay Intertechnology, Inc. Other N-channel andP-channel MOSFETs may be used depending on the specific application.

Still referring to FIG. 5, the microprocessor 495 generates a chargeenable 495D voltage across resistor 517 which drives the gate ofN-channel MOSFET 516 which divides the charge bus 489A voltage acrossresistor 514 in proportion the combined resistance of resistors 514 and515 which in turn enables P-channel MOSFET 512 allowing the applicationof charge bus current to the battery 102, 202 by way of batteryoutput/input 503. Charge bus 489A is isolated from the batteryoutput/input 503 by a diode. A representative diode which may be used isa Schottky Diode such as a 10A Dual Low Vf Schottky Barrier Rectifiermade by Diodes Incorporated. Wherever such Schottky Diode applicationsarise within the intelligent power supply, one may substitute an activediode oring circuit. This type of circuit prevents reverse current flowin the same way such flow is blocked by the diode. It has the furtheradvantages of allowing forward current flow with a forward voltage dropwhich is substantially less than the diode. The active oring approachtherefore provides diode functionality with reduced cost in terms ofsystem power. One exemplary implementation of the active oringalternative is based upon a control IC such as International Rectifier'sIR5001s used in conjunction with an appropriate N-channel MOSFET.

Still referring to FIG. 5, the microprocessor 495 multiplexes batteryinformation signals from the battery information bus 495B and, asexplained previously, is capable of converting analog to digitalsignals. Reference numeral 501 indicates a voltage applied by a voltageregulator 497A. The microprocessor de-asserts an information disablesignal 495F allowing current to flow through resistor 528 and a lightemitting diode 532A coupling the output of battery 102, 202 acrossresistor 530 in proportion to the resistance of 530 in proportion to thecombined resistance of resistors 529 and 530 which drives the gate ofN-channel MOSFET 531 effectively connecting the battery information bus495B with a battery information interface 530A to the effect of sensingone or more parameters about the battery such as temperature. Thebattery information interface may, for example, be a temperature sensorsuch as that denoted earlier by reference numerals 133, 144.Alternatively, the battery information interface may provide access to amore or less complex communications protocol supported by a particulartype of battery or energy pack, such protocol being based upon analog ordigital modulated or un-modulated physical signaling mechanisms inconjunction with protocol software used to achieve higher levels oflogical communications between the microcontroller of the intelligentpower supply and a peer process or controller within the battery orenergy pack. This approach allows a very wide range of informationexchange including status information from the energy pack as well ascontrol and command information to the energy pack to be communicated.One known example of a communications protocol used in the exchange ofinformation with batteries is the SMBus. SMBus is the System ManagementBus defined by Intel® Corporation in 1995. SMBus or other possibleprotocols may require multiple signals (e.g. clock and data signals).Although only one interface signal 531 is depicted in FIG. 5 it isintended that the battery information bus 495B may be multiple signalsin width and that additional switches will be included as required tomultiplex additional info bus signals when they are used.

In addition to the obvious benefits of accessing battery information viathe battery information bus 495B, the possibility to implement securityand anti-theft functions are also important. In on scheme, energy packs(battery packs) would be disabled and unusable whenever they are outsideof and independent of the power supply system. Using information secretto each power supply, and communicating via the battery information bus495B, the power supply would selectively enable such energy packs onlyupon their insertion and recognition by the system. This wouldeffectively thwart any motivation for theft of such packs (since theybecome useless once removed). Along similar lines, when the systemdetects that a pack or packs have been removed as evidenced either byvoltage deficiency at the respective location on the battery monitor bus495A or cessation of communications at the respective location on thebattery information bus 495B, the power supply can note such removalsand report same as an alarm or information event to its networkmanagement entities. Finally, the insertion of unauthorized orcounterfeit packs may similarly be detected and reported.

Still referring to FIG. 5, reference numeral 501 is a voltage sourcefrom the voltage regulator 497A and the microprocessor 495 generates apower enable 495C voltage across resistor 511 voltage to drive the gateof N-channel MOSFET 507 allowing the division of battery voltage acrossresistor 510 in proportion to the sum of the resistance of resistor 509and resistor 510. The divided voltage is applied to the gate ofP-channel MOSFET 508 permitting conduction of current from the batteryoutput/input 503 to the direct current battery bus 450A. In general, theswitching circuit just described using MOSFETs 507 and 508 inconjunction with various resistors, voltage sources, and control signalsis representative of one implementation for switching functions depictedin other parts of the figures such as elements 413 and 425 in FIG. 4 andeven elements 550 and 550A in FIG. 5 itself. Diode 505 permits forwardcurrent in the direction of the dc battery bus only and could beimplemented at least using either the Schottky Diode or active oringcircuits mentioned previously in conjunction with the discussionsurrounding charge bus 489A.

Still referring to FIG. 5, a switch 550 is schematically indicated asinterconnected with Rsense bus 560. A Kth battery interface circuit isillustrated as being connected to the DC Battery Bus 450A to emphasizethat there are K battery interface circuits. The Kth battery is alsointerconnected via switch 550A to Rsense bus 560.

The structure and function disclosed herein can be used in automobilesand other vehicles. Specifically, the structure and function of theinstant invention can monitor the performance of a Lithium-ion poweredautomobile to determine the performance of individual battery packs orindividual battery cells within the packs. This enables the clusters orgroups of Lithium ion batteries to be used in a vehicle such that theseclusters operate and function as a “gas” tank or more appropriately asan “energy” tank. The microprocessor used herein notifies the driver ofthe status of his energy tank thus informing the driver that it is timeto refuel. The driver then stops at a service station where one or moreof his battery packs is removed from his vehicle and exchanged withfreshly charged battery packs or groups or clusters of battery packs.The driver is given credit for the energy stored within his packs orclusters or groups of battery packs. In this way operation of batterypowered electric vehicles becomes just like operation of a gasolinedriven vehicle.

All of the switching (selectively coupling) performed by the batteryinterface circuits is programmable with respect to operation of the rackof batteries and also with respect to other system inputs and outputs.

FIG. 7 is a schematic 700 illustrating up to K removable cartridgeenergy packs/battery packs 701, 702, 703 selectively interconnected withN load buses 706, 707, 708, a sense resistor 603, an Rsense bus 560, acharge bus 489A and a monitor bus 495A. A plurality of switches 710 areshown each of which is controlled by microprocessor 495. MCU 495receives inputs as described previously in connection with FIG. 5 andalso receives inputs as indicated schematically in connection with FIGS.4, 4A, 4B and 4C including voltage, current, and temperature inputs.FIG. 7 also illustrates diodes 711 to inhibit reverse current flow withrespect to each load bus 706, 707, 708 and the charge bus 489A. The loadbuses 706, 707, 708 may be selectively disconnected from the load by themicroprocessor.

FIG. 6 is a schematic 600 for obtaining load and removable cartridgeenergy pack/battery pack 102, 202 information for use by themicroprocessor 495. Battery 102, 202 includes an energy source Vbat 607and an internal resistance Re 608. Monitor 602 measures the terminaloutput voltage across the battery 102, 202. The battery 102, 202 isselectively interconnected (coupled) by switch 604 with a user definedload or loads 601 and is also selectively interconnected (coupled) byswitch 605 with a sense resistor 603 of known resistance.

Still referring to FIG. 6, three measurement processes are implemented.In the first process or first algorithm, the battery 102 is selectivelyconnected to and disconnected from the user defined load 601 usingswitch 604. Voltage measurements are made by the voltage monitor 602with switch 604 closed to obtain the voltage across the user definedload (Vcc—voltage closed circuit user defined load) and with the switchopen to obtain the terminal output voltage across the battery 102 (Voc,voltage open circuit). In this process switch 605 disconnects senseresistor 603 from the battery 102 at all times.

Still referring to FIG. 6, in the second process or second algorithm,the user defined load 601 is selectively disconnected by switch 604 fromthe battery 102 while voltage measures are being taken. Voltagemeasurements are made by the voltage monitor 602 with switch 605 closed(Vcc-sr, voltage closed circuit-sense resistor) and voltage measurementsare made by the voltage monitor 602 with the switch 605 open (Voc,voltage open circuit).

Still referring to FIG. 6, in the third process or third algorithm, theuser defined load 601 is selectively connected to the battery by switch604 at all times. Switch 605 is selectively connected to anddisconnected from the sense resistor 603 using switch 605. Voltagemeasurements are made across the sense resistor 603 in parallel with theuser defined load Vcc(sr∥ul)(voltage closed circuit, sense resistor∥userdefined load) when the switch 605 is closed. Voltage measurements arealso made across the user defined load Vcc(ul)(voltage closedcircuit-user defined load) when switch 605 is open.

In the first and second algorithms the closed circuit current, forexample, the load current (Icc) may be obtained by:Vload=Vbat−Vrbat  (1)

where Vload=Vcc(ul)(voltage closed circuit-user defined load) or whereVload=Vcc(sr)(voltage closed circuit-sense resistor) and Vrbat is thevoltage drop across Re during the condition when Vload is established,and where Vbat=Voc, substitutingVoc−Vcc=Vrbat  (2)assuming Rbat (Re) is known, dividingVrbat/Rbat=Icc  (3)

Alternatively, assuming the load current, Iload, whether it be throughthe user defined load (ul) or the sensor resistor load (sr), is known,thenRe=(Voc−Vcc(ul)/Iload or, Re=(Voc−Vcc(sr))/Iload  (4)

In the third algorithm, Rbat (Re) and Rsense (Rs) are known from priordetermination. We measure Vcc(ul) (voltage closed circuit-user definedload) and Vcc(sr∥ul) (voltage closed circuit, sense resistor∥userdefined load). Icc(ul) (current through the user defined load) isdetermined as follows:Vcc(ul)=Vbat*Rload/(Rload+Rbat)  (5)and,Vcc(ul∥sr)=Vbat*(Rload∥Rsense)/((Rload∥Rsense)+Rbat), where  (6)Rload∥Rsense=Rload*Rsense/(Rload+Rsense), solving for Rload  (7)Rload=Rbat*(Vcc(ul)−Vcc(sr∥ul))/[Vcc(sr∥ul)(1+Rbat/Rsense)−Vcc(ul)],  (8)and, once Rload is known then the current through the load and thebattery can be determined by dividing Vcc(ul)/Rload=Iload.

The current through the parallel combination of Rsense and Rload can becalculated by:Icc(ul∥sr)=Vcc(ul∥sr)/(Rload*Rsense/(Rload+Rsense)  (9)

In the third algorithm, if the load current, Iload, through Rload isknown by measurement, then Rload can be calculated by:Vcc(ul)/Icc(ul)=Rload,  (10)and once Rload is known, then Rbat=Re can be calculated from equation 8if Vcc(ul), Vcc(sr∥ul) and Rsense are known.

If the current through the user defined load is known and if theinternal resistance of the battery, Re, is known then a calculation ofthe voltage drop across the internal resistance of the battery can bemade. Batteries, and in particular Li-Ion batteries, may be damaged ifthey are operated below a critical voltage which inferentially indicatesthat the state of charge is too low. Current flow through the battery,therefore, provides valuable information about the battery enabling theuser or system to decide whether a measured terminal voltage is due to ahigh load or is due to a low state of charge operation. Li-Ion batterieswhich are drained below a protective state of charge may be permanentlydamaged. Therefore, the microprocessor may selectively disconnect aparticular back-up battery if its state of charge is too low. Themicroprocessor may decide to charge the particular battery if its stateof charge is approaching a critical value or the microprocessor maysupply charge current which is summed with the current available fromthe particular battery of interest and continue the contribution (albeitdiminished now by the amount of the added charge current) of thatbattery as an energy source.

If the discharge current through the load, Iload, is known or if thecharge current into a battery, Icharge, is known by a current measuringdevice then Re can be determined as indicated above. Re is importantbecause it varies as a function of temperature, age, and otherconditions of the battery and may indicate trouble with or end of lifefor the battery. Therefore, the microprocessor may selectively disable aparticular back-up battery depending on a calculated Re, or themicroprocessor may signal an alarm event to inform the networkmanagement entity of the inferred problem with a particular battery. Anintermediate possibility exists wherein the microprocessor deploys oruses (connects to loads) each battery with a duty cycle proportional insome predictable way to the inferred health of each battery. Forexample, an older failing battery will be used seldom (but not gocompletely unused) compared to a brand new battery having maximal energywhich will be used often and preferentially. In this way, for a givenpopulation of K batteries in the system, the microprocessor may proceedto deploy these batteries in such a way that tends to equalize thehealth or electrical status of all. Another valuable function of thesystem rests on the microprocessor's ability, via the measurements ofvoltage, current, and temperature, to estimate the absolute capacity ofeach particular battery or energy source during a discharge followed bya charge cycle. The microprocessor can connect a particular battery to aload until such time as its state of charge is seen to be approaching 0%(fully discharged). From that point, the microprocessor can disconnectsaid battery from the load and connect said battery to the charge bus.The microprocessor can monitor the current over the time of charge ofthe particular battery until an appropriate charge termination eventsuch as a voltage or temperature event indicates completion of chargeand arrival by the battery at the 100% state of charge level. The recordof current multiplied by time increment during the charge cycle thenindicates the electric charge imparted to the battery in thetransformation from 0% to 100% state of charge. In the case of acoulombic efficient battery chemistry such as lithium-ion, the chargetransferred will rather directly reflect the charge capacity at 100%state of charge. This capacity compared to the corresponding capacity ofa new, unused battery will in turn reflect the age or converselyremaining useful life of the battery. For example, when the batterycharge capacity at 100% state of charge falls below 50% of the newcharge capacity, the battery may be nearing the end of its useful life.In other cases where the chemistry is not 100% charge efficient, the100% state of charge energy will nonetheless provide insight andinference into the state of health of the battery. As mentioned earlier,in either case whether the battery chemistry is charge efficient or not,estimation of the inherent resistance of the battery (Re) in light ofthe prevailing temperature of the battery will also provide valuableinference into the state of health of the battery.

FIG. 4 is a schematic 400 illustrating an alternating current input 401converted to a direct current by an AC/DC converter 406. The output 406Aof the converter 406 is selectively switched by switch 407 tointerconnect with a direct current intermediate bus 412B and/or isselectively switched by switch 408 to a second direct current bus 412Aand/or is selectively switched to a third direct current bus 412C byswitch 409. Output 406A of the converter is coupled via connection 403to the MCU 495 (see, FIG. 4C).

All of the elements indicated and described on FIGS. 4, 4A, 4B and 4Care mounted on the motherboard (printed circuit board). All of theelements are scalable. For instance, one example of the system mayprovide 1000 Watt-hours of energy and can supply power nominally at 150Watts. Another example may supply 4000 Watt-hours of energy and cansupply power at 800 Watts, etc.

Still referring to FIG. 4, diode 423 ensures that current flows from theoutput of the AC/DC converter to the direct current intermediate bus412B but not the reverse. Diodes 410 and 411 similarly ensure thatcurrent flows from the output of the AC/DC converter to the seconddirect current bus 412A and the third direct current bus 412C,respectively, but inhibits flow in the reverse direction. The AC inputis converted using AC detect 404 into a direct current voltage to whichmicroprocessor 495 is selectively coupled to measure allowing thevoltage 405 of the AC input to be thereby estimated. Current flowingthrough the AC input 401 is sensed by a current detector andmicroprocessor 495 is selectively coupled to measure the current 405A.The output 406A of the AC/DC converter is selectively coupled to themicroprocessor to measure the voltage 412.

The AC/DC converter may for example be a 150 Watt enclosed single outswitcher capable of accepting 85-264 VAC input with a 24 VDC output,manufactured by Cosel. Other AC/DC converters may be used which arecapable of converting a larger or smaller VAC input and are capable ofproducing much higher or lower VDC outputs at much higher or lowerwattage. Virtually any AC input may be accepted by the power supplydevice and converter with a properly selected converter.

Still referring to FIG. 4, the current output of the AC/DC converter 406is sensed and selectively coupled to the microprocessor to measure thecurrent 412D. A temperature sensor may be located on the motherboard inproximity to the AC/DC converter and is selectively coupled with themicroprocessor to measure the temperature 412E.

The direct current bus may operate over a wide range of voltages andcurrents as determined by user specifications and the requirements of aparticular application. Typical voltages of the direct currentintermediate bus 412 are expected to be in the 12-30 VDC range to enablesupply of the intermediate bus not only from an AC/DC converter but alsofrom back-up energy sources such as removable cartridge direct currentbatteries which may or may not be dual purpose batteries.

Still referring to FIG. 4, the direct current intermediate bus 412B isselectively interconnected by switch 413 to a direct current toalternating current converter 414 providing an alternating currentoutput 417 and/or the direct current intermediate bus 412B isselectively coupled by switch 425 to a first direct current output 421and/or the direct current intermediate bus is selectively coupled viaswitch 425A to a third direct current to direct current converter 427 toprovide second 426 and third 428 direct current outputs. Voltage output424, current output 424A and temperature 424B of the direct current todirect current converter 427 are monitored by the microprocessor. Theinput voltage 419 to the direct current to alternating current converteris monitored by the microprocessor 495. The alternating current outputvoltage 416 of converter 414 is converted by detector 415 and monitoredby the microprocessor, as is the output current 416A. Temperature 416Bof the direct current to alternating current converter 414 is alsomonitored by the microprocessor. The voltage 420 and current 420A of thefirst 421 direct current output are monitored by microprocessor 495.

The direct current to direct current converters may, for example be10-32 VDC converters supplied by ACON. The AC/DC inverter may be a 150Watt inverter supplied by CD Media Corp.

When the phrase “monitored by the microprocessor” is used herein itmeans that the microprocessor 495 converts a parameter such as voltage,current or temperature from an analog to a digital signal and thenprocesses that signal data according to a well defined algorithm.

Selective coupling or connection is accomplished by the microprocessorand its control of the switches which interconnect the buses to thesources. As described above, the output of the AC/DC converter is bused406A to switches 407, 408 and 409 in parallel leading to respectivebuses. The microprocessor controls switches 407, 408 and 409 (which maybe implemented using P-channel MOSFETS or other suitable electronic ormechanical switches) according to system voltages, currents andtemperatures of the inputs (including the back up batteries), outputs,buses, and converters according to pre-defined programming or specifiedmanual control. For instance, there may be situations when the userdefines to preferentially use a particular input despite theavailability of other inputs. An example may be a military applicationwhere it is decided to use the back up batteries as the energy sourcedespite the availability of a direct current source from a vehicle so asto not deplete the batteries of the vehicle in a combat situation. As afurther example, the microprocessor may infer from the level of the DCinput representing the vehicle input whether or not the vehicle isrunning and correspondingly whether or not the vehicle's chargingcircuit is actively supplying current. With this information, the systemcan implement a control plan wherein the power supply load is sourced bythe vehicle when it is running, by the backup batteries when the vehicleis not running, and then again by the non-running vehicle battery afterthe backup batteries are depleted to a specified level (say 5% state ofcharge). Finally, the load can be disconnected when both the vehicle andbackup batteries have reached a pre-defined low state of charge. In thisway, the intelligent power supply has maximized the run time of the loadwhile maintaining the best disposition of vehicle reserve batteryenergy, and in the end, at least sufficient residual vehicle batteryenergy to guarantee the ability to start the vehicle.

FIG. 4A is a schematic 400A of a first 430 direct current input, asecond 439 direct current input and a third direct current input 450A(battery pack array) each of which is selectively coupled to the directcurrent intermediate bus 412B, and/or the first direct current bus 412Jand/or, the second direct current bus 412A and/or the third directcurrent bus 412C. The first direct current input 430 is bused 430A andis selectively coupled by switch 431 with the direct currentintermediate bus 412B and/or is selectively coupled via switch 432 withthe first direct current bus 412J and/or is selectively coupled byswitch 432A with the second direct current bus 412A and/or isselectively coupled by switch 433 with the third direct current bus412C. Diodes 434, 435, 436, and 437 are located downstream from theirrespective switches and ensure current flow from bus 430A to therespective buses and not the other way around. Voltage 438 and current438A supplied by the first direct current input 430 is monitored by themicroprocessor 495.

Third direct current input is a battery pack described herein above inregard to FIGS. 1, 2, 5, 6 and 7. An array of batteries arranged inparallel supplies power to bus 450B. The individual batteries may be ofdifferent individual voltages and chemistries and their use iscontrolled by the battery interface circuits described above employing aselective coupling system together with diode protection.

Still referring to FIG. 4A, the third direct current input 450A is bused450B and is selectively coupled by switch 451 with the direct currentintermediate bus 412B and/or is selectively coupled by switch 452 withthe first direct current bus 412J and/or is selectively coupled byswitch 453 with the second direct current bus 412A and/or is selectivelycoupled by switch 454 with the third direct current bus 412C. Diodes455, 456, 457, and 458 are located downstream from their respectiveswitches and ensure current flow from bus 450B to the respective busesbut inhibit the reverse flow. The switches may be P-channel MOSFETs andthe diodes may be Schottky diodes. Voltage 459 and current 459A suppliedby the third direct current input 450A is monitored by themicroprocessor 495. Each of the direct current inputs 430, 439, 450A.The AC/DC converter 406 and the first and second converters 475, 483 areprotected against over-current and over-voltage conditions using devicessuch as fuses or PTC thermistor devices and Metal Oxide Varistars (MOVs)or other transient voltage suppression techniques.

Still referring to FIG. 4A, charge bus 489A is interconnected with thethird direct current input so as to enable selective recharging or loadsharing as described above in connection with FIG. 5, the batteryinterface circuit.

Still referring to FIG. 4A, the second direct current input 439 is bused(439A) and is selectively coupled by switch 440 with the direct currentintermediate bus 412B and/or is selectively coupled by switch 441 withthe first direct current bus 412J and/or is selectively coupled byswitch 442 with the second direct current bus 412A and/or is selectivelycoupled by switch 443 with the third direct current bus 412C. Diodes444, 445, 446, and 447 are located downstream from their respectiveswitches and ensure current flow from bus 439A to the respective busesbut not in the reverse direction. The switches may be P-channel MOSFETsand the diodes may be Schottky diodes. Voltage 448 and current 448Asupplied by the third direct current input 450A is monitored by themicroprocessor 495.

Still referring to FIG. 4A, third direct current bus 412C is coupled tofourth direct current output 470 and its output voltage 470A and current470B are monitored by the microprocessor 495. The third direct currentbus 412C may also be selectively coupled via switch 474 to the fourthdirect current to direct current converter 473 which outputs to thefifth 471 and sixth 472 direct current outputs. Voltage 473A and current473B and the temperature 473E of the converter 473 are monitored by themicroprocessor 495.

FIG. 4B is a schematic 400B illustrating the first direct current bus412J interconnected with a first direct current to direct currentconverter 475 and the output 475A of the first direct current to directcurrent converter 475 selectively coupled to the direct currentintermediate bus 412B and/or the third direct current bus 412C and/orthe direct current charge bus 489A. The output bus 475A is selectivelycoupled via switch 477 with the direct current intermediate bus 412Band/or is selectively coupled via switch 478 with the third directcurrent bus 412C and/or is selectively coupled via switch 479 with thedirect current charge bus 489A. Diodes 480, 480A, and 481 are locateddownstream from their respective switches and ensure unidirectionalcurrent flow from bus 475A to the respective buses. The switches may beP-channel MOSFETs and the diodes may be Schottky diodes. Voltage 482 andcurrent 482A of the first direct current to direct current converter 475as well as temperature 482E in the proximity of the converter aremonitored by the microprocessor 495.

Still referring to FIG. 4B, the second direct current bus 412A isinterconnected with the input of a second direct current to directcurrent converter 483 and the output 483A of the second direct currentto direct current converter 483 is selectively interconnected to thedirect current intermediate bus 412B and/or the third direct current bus412C and/or the direct current charge bus 489. The output bus 483A andis selectively coupled via switch 484 with the direct currentintermediate bus 412B and/or is selectively coupled via switch 485 withthe third direct current bus 412C and/or is selectively coupled viaswitch 486 with the direct current charge bus 489A. Diodes 484, 485, and486 are located downstream from their respective switches allowingcurrent to flow from bus 483A only in the direction of the respectivebuses 412B, 412C, and 489A. Once again, the switches may be P-channelMOSFETs and the diodes may be Schottky diodes. Voltage 490 and current490A of the second direct current to direct current converter 483 aswell as temperature 490A in the proximity of the converter are monitoredby the microprocessor 495. The charge bus 489A is interconnected withthe removable cartridge energy pack rack.

Again referring to FIG. 4B, it can be seen that microprocessor 495 hasthe ability via converter output voltage control interface 495X tocontrol the output voltage of DC/DC converter elements 475 and 483. Themicroprocessor can decide, upon measuring the voltages and currents indifferent channels within the system, a best output voltage adjustmentfor each DC/DC converter such that the mix of power provided by eachchannel is thereby optimized according to some pre-defined goal of thesystem. For example, a goal of utilizing 30% current from first DC input430 along with 70% current from third DC input representing backupbatteries 450A can be realized by switching first DC input to powerfirst DC/DC converter, switching third DC input to power second DC/DCconverter, and adjusting first DC converter voltage output and second DCconverter voltage output up or down as required so that the currentsensed at 482A compared to the current sensed at 490A are in theproportions 3:7. The scenario described is one from the category ofcontrol algorithms allowing intelligent power mixing. As compared to anall or nothing contribution decision represented by a simple switch,power mixing allows a continuum of adjustments regarding how much poweris utilized from each source.

The converter voltage output control can be further understood byviewing FIG. 52 signals DAC_DATA, DAC_SCLK, and DAC_SYNC_1 emanate fromU34 MCU and go to FIG. 57 D1 DAC (Digital to Analog Converter) U50 wherefour analog voltage outputs are generated, DAC_DC1_TRIM_1 throughDAC_DC4_TRIM_1. These signals route for amplification to respectiveamplifier circuits U48, U49, U51, and U52. These amplifiers in turngenerate voltage control output signals DC1_TRIM_1 through DC4_TRIM_1.These signals connect to the respective DCDC converter TRIM input pinson FIG. 39 (DCDC1 U3 or U4) FIG. 41 (DCDC2 U5 or U6) FIG. 58 (DCDC3 U57)and FIG. 46 (DCDC4 U11).

Power mixing is important as one or more direct current to directcurrent converters are arranged in an oring fashion. For example, a userdefined direct current input source may be combined with the arrayedbattery direct current input source comprising a plurality of batteriesfor the purpose of supplying one or more user selected loads inparallel. A first direct current to direct current converter may becoupled with the user defined direct current input source and a seconddirect current to direct current converter may coupled with the arrayedbattery direct current input source, and, as just described the firstand second converters have adjustable output voltages.

A microprocessor coupled to the first and second converters controls theoutput voltages of the converters and the contribution of each of thedirect current sources to the energy flowing on the DC bus(es) fed byboth converters. Secondly, the converters may be coupled together asillustrated in FIG. 4B using diodes such as Schottky diodes. Since themicroprocessor measures the current and voltage output by each converteras well as the current and voltage of the respective inputs supplyingsaid converters, it is possible for the microprocessor to adjust theoutput voltages of each converter to achieve several end goals includingcontrolling the current, voltage, or power of each input, controllingthe current, voltage, power, or temperature of each converter, and/orcontrolling the current, voltage, or power of the load bus(es). Finally,since the voltages of the converters are controlled according to netinput, converter, or load characteristics measured by the microprocessoron a continuous basis, the control process will cancel out varyingcharacteristics such as forward voltage drop of the diodes or varyingcharacteristics of the converters of other components employed in thecircuits. That is to say that the control process has the advantages ofa closed loop process running to measured as opposed to predictedresponse variables.

The functions of measuring currents in the respective input, conversion,and output channels is further illuminated. Shunt resistors are placedin the negative leg of the component whose current is to be measured,e.g. FIG. 46 U11 pin 8 (VOUT_Negative) connects to point DCDC4_OUT_N. AtFIG. 56 this signal connects to GROUND via a shunt resistance formed byresistors R207 and R208 in parallel (0.0025 ohms net). The small voltagedeveloped across this shunt resistance is proportional to the currentflowing and is amplified in the example by differential amplifier formedaround Op Amp U47. The output voltage from U47 is scaled suitably formeasurement by the MCU Analog to Digital converter and is enabled ontothe measurement bus for that purpose via an electronic switch formed byQ108 and Q109. In this way the MCU can determine the current in any ofthe “I” circled points (e.g. 490A, 482A) networked to the microprocessorinterface 461 at any moment in time (see FIGS. 4B and 4C).

Voltage measurements (e.g. 490, 482) are made similarly by appropriatescaling by resistive voltage dividers and electronic switch multiplexingonto an ADC input channel of the MCU representing the interface 460again in FIGS. 4B and 4C.

Temperature measurements (e.g. 490E, 482E) are made similarly by usingNTC thermistor devices in a voltage division network such that thevoltage measured by the MCU via another multiplexed ADC input channelrepresented by interface 462 in FIGS. 4B and 4C is proportional to thethermistor resistance which in turn is non-linearly indicative of thethermistor's temperature.

Exemplary modes of switch control are disclosed herein. The many systemswitches such as those depicted in FIGS. 4, 4A, 4B, 4C, and 5 arecontrolled via digital signals developed in the serial to parallel dataconversion circuits at FIGS. 47-50. Using a few interface signals, theMCU can serially program these daisy chained serial to parallelconversion circuits and cause their many parallel outputs to update tothe desired control states (on or off, controlling whether correspondingswitches are open or closed).

FIG. 4C is a schematic 400C illustrating the microprocessor 495, itspower supply (voltage regulator) 497A and interfaces. The voltageregulator 497A may be a 3.3 VDC regulator from National Semiconductor.The voltage regulator outputs 3.3 VDC to terminals represented byreference numeral 501 in FIG. 5, the battery interface circuit. Thealternating current to direct current converter 403, the first directcurrent input bus 430A, the second direct current input bus 439A, thethird direct current input bus 450B and an independent replaceablebattery 497 are supplied in parallel to the voltage regulator to ensurepower 497A and control of the power supply device. Voltage 496 of thebattery is monitored by the microprocessor to inform the user thatbattery 497 is low. Also schematically indicated are interfaces 464,465, 466, and 467 with a plurality of back-up energy subsystems whichmay be a rack of rechargeable batteries. Voltage 460, current 461 andtemperatures from the individual components mounted on the mother boardare indicated as well as a time base for clocking measurements,controlling the switching and communicating internally and externally.The interface 495X converter output voltage control interface whichallows the microprocessor to control and adjust the voltage (and therebycurrent) of each DC/DC converter in the system is also depicted.

Still referring to FIG. 4C, other inputs to the microprocessor includesa door open sensor 491, power supply ambient temperature 492, statusLEDs 494, fan interface 498, serial interface 499 and Ethernet interface499A. The serial interface may be used in conjunction with a servicecomputer to interface to all status and control features of theintelligent power supply. Likewise, the Ethernet interface may be usedfor local interface and inquiries or may be used to connect theintelligent power supply to a network whereby its management functionsmay be implemented from client computers anywhere in the world havingnetwork access. Switches 493 indicate globally the control of allswitches on the motherboard for directing and routing power, and allswitches for all of the battery interface circuits. There may also bepushbutton or other user input switches which are sensed and uponactuation responded to by the power supply controller.

FIG. 8 is an illustration 800 of the processing steps used in aconfigurable microprocessor control algorithm including: measuringvoltages and currents of I inputs, Q outputs, M buses, and K back-upbatteries 801; measuring temperatures of L converters and K back-upbatteries 802; analyzing measurements to determine optimal powerswitching 803; changing up to S switch states and V converter outputvoltages as required to optimize power distribution 804, andperiodically updating all measurements and repeating all of the steps805.

FIGS. 9A and 9B deserve in depth study as many of the features,benefits, and potential uses of the scalable intelligent power supplyinvention are depicted therein. Scalable Intelligent Power Supply blocksare shown 901A through 906A, each having a unique Internet Protocol (IP)address assigned as exemplified at 906I. The unique IP address coupledwith the Ethernet interface shown at 499A along with appropriatesoftware contained in MCU 495 allows each power supply to communicate ina network fashion with each other, other equipment such as IPperipherals such as 901C, 902C, or 903C, as well as management computersand systems such as those depicted at 905B and 906B. This communicationsallows information to be exchanged pertaining to the status or operatingmode of the power supplies or other equipment. For example, a statusreport screen is depicted schematically at network management computer905B with related close up view in 905H. 905H depicts a reportoriginating from power supply 902A having IP address 192.300.282.3. Itcan be seen that the status information includes details pertaining tothe voltages, currents, temperatures, and utilizations as applicable foreach input, converter, output, or battery within said power supply. Thatfact that this power supply is operating on behalf of seismometer 3 aswell as its location in coordinates of latitude and longitude is alsoreported. This information is beneficial to efficient management of theoverall system as well as each particular node. Other computersincluding the management computer at 906B and ad hoc computers such aslaptops in the field can also access this information. Appropriatesecurity mechanisms including information encryption and passwordprotection are envisioned as an integral part of the intelligent powersupply system.

Several power supply use scenarios are depicted in FIGS. 9A and 9B.Scenario 1 at 901 depicts a power supply interfaced to a wireless router901B and a video camera 901C capable of transmitting video over InternetProtocol (VOIP). The interfaces include a power interface 901F to theVOIP camera and both a power 901F and an Ethernet interface 901G to thewireless router whereby its Internet Address 901I renders it reachablefrom anywhere on the Wide Area Network (WAN) 908. The power supply isalso interfaced to a street light 901D whereby it receives input powervia interface 901E. The specification for the scenario contained indescriptive block 901 indicate that the combined load requirements forthe wireless router and the VOIP camera add up to 55 Watts. The outputpower type might be AC or DC voltages of appropriate levels dependingupon the requirements of the load devices. The scenario also specifiesthat input power from street light 901D will be intermittent, i.e.,switched on 8 hours and off 16 hours of each day. The power supply willtherefore power the camera and router from battery backup power for 16hours while the street light power is disabled (presumably duringdaylight hours) and will power the camera and router loads as well asrecharge the backup batteries for 8 hours while the street light poweris enabled. Should power fail unexpectedly during any interval, thepower supply will switch instantly to backup battery power so thatoperation of the loads goes without interruption until input power isre-established. At all times, the power supply will measure and estimatethe amount of backup energy available and compare this to the amount itknows to be required for operation to proceed without interruption inthe normal course of power cycling (8 hours on, 16 hours off). It willbe an important feature of the power supply system to be able to predictenergy deficiencies and subsequent power inadequacies and report same asan information or alarm event to its network management entities well inadvance of such an event occurring. This report coupled with thecapability of hot-swappable battery packs will allow maintenancepersonnel to visit the location in advance of power running out and swapan adequate complement of worn batteries for freshly charged ones topreclude the power failure.

Often peripherals such as the VOIP camera 901C involved in outdoordeployments such as the street light scenario 901 will require ancillaryheating under cold environmental conditions in order to maintain correctoperation. This requirement is conventionally addressed with theaddition of a heater device which would also be powered by the powersupply. This increases the power level and backup energy required in thepower supply accordingly, an appropriate heater costing an additional 20to 30 Watts by way of example. The opportunity arises, with theintelligent power supply, to accomplish the requirement for ancillaryheat more efficiently. In particular, heat is generated inside the powersupply as a result of operation of voltage conversion units, charging ofbatteries, and power dissipation in the electronic and electricalcomponents of the power supply system in general. If the power supply isconnected via a duct or conduit such as that schematically depicted by901J, air warmed within the power supply by aforementioned phenomenonmay be conveyed to the peripheral device requiring ancillary heat. Theducting may be accomplished coaxially in the conduit already positionedto convey the power cables or may occur via a separate conduit placedexpressly for the heating purposes. A fan inside the power supply,controlled by MCU 495, may be used to produce the desired air flow. Thepower supply may control the amount of warm air, if any, based upon itsmeasurement of external temperature, its measurement of its internal airtemperature, and communications of information via its Ethernetconnection with either the peripheral requiring heat and/or its networkmanagement systems.

Scenario 2 at 902 depicts what might be instrumentation (seismometer902C) deployed in a sunny, remote location such as the Americansouthwest desert. In this case power supply 902A powers the seismometer902C as well as a wireless network access device 902B. Power will beavailable to the power supply via solar panel 902D, ordinarily over thecourse of 12 hours of daylight only. During the dark periods the powersupply must operate from its backup energy sources. Cloudy days mayoccur when the “dark period” is extended from 12 to perhaps 48 or morehours. Therefore, a typical deployment may utilize additional backupenergy frames such as those depicted in FIG. 1N to achieve the requisitebackup energy reservoir needed for prolonged, input-power-deprivedoperation.

Scenario 903 depicts a mobile, vehicle born application wherein powersupply 903A derives input power from vehicle 903D when available,charging its backup energy sources and powering its loads includingnetwork access device 903B and Voice over IP telephone 903C. The powersupply may be programmed to be cognizant of the state of the vehiclepower system. The MCU 495 may infer from voltage measurements of the DCinput coming from the vehicle whether or not the vehicle is running andactively charging its own battery. In the case where the vehicle isrunning, its power may be the preferred source. In the case where thevehicle is not running, it may be preferred to power the loads from thebackup energy sources within the power supply thus preserving thevehicle battery maximally. It may also be possible to remove(disconnect) from the vehicle altogether and transport the power supplyalong with it wireless router and telephone to a different location,perhaps another vehicle or outpost having a different power sourceavailable. It may then be possible to reconnect the power supply to anew power source when available and re-charge any backup energy that wasused in the transition between power sources all the while operating thenetwork interfaces and telephone (or other peripherals) withoutinterruption.

Scenarios 904, 905, and 906 depict power supply applications whereininput power is provided by a dedicated, full time AC outlet. The onlyinterruptions expected are those interruptions that occur on occasion inthe utility grid (black out or brown out events). These interruptionsmay be infrequent and of typically short duration. Therefore, it ispossible that the backup energy required in these power supplies 904A,905A, and 906A may be substantially less than that required in thepreviously described scenarios. The advantage of the scalable powersupply architecture would then allow few backup energy packs to bepopulated (a partial rack full) and therefore allow a lower cost for therequired system. Alternatively, one or more of the fixed computers ornetwork interfaces may desirably have extended backup time to cover anextended power outage. The precise number of energy packs and/or thedesired number of frames of power packs may be applied to each node asdesired or required on a node-by-node energy/backup time requirementbasis. Finally, it may be possible that power outages may exceed theinterval for which backup power has been designed. The power supply hasthe advantages of being able to accurately predict the amount of backuppower remaining, communicate anticipated backup energy deficits well inadvance via its network interface, and remain functional for additionalextended periods by the mechanism of hot swapping energy packs viamaintenance intervention.

FIG. 10 illustrates exemplary power supply generation circuits whereinreference numeral 1001 indicates a negative 3.3V supply and referencenumeral 1002 indicates a positive 6.6V supply.

FIG. 11 illustrates exemplary microprocessor-controlled batteryinterface circuits, detailed example, (1 of 20). Reference numeral 1101is the discharge control switch circuitry, as described in connectionwith FIG. 5 above. Charge control switch circuit 1102 is shown inexemplary fashion and has been described in connection with FIG. 5above. Battery monitor bus multiplex circuit 1103 has been describedabove in connection with FIG. 5. And, battery information bus switchcircuit 1104 has been described above as well in connection with FIG. 5.Connector 1105, by which battery bus and switch control signals areconnected with other system elements including the microprocessor andpower conversion units, is illustrated in FIG. 11. FIGS. 12 through 30,are exemplary of battery interface circuits like the one just describedin connection with FIG. 11 and FIG. 5. Reference numerals 1200, 1300,1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500,2600, 2700, 2800, 2900 and 3000, illustrate the nineteen additionalmicroprocessor-controlled battery interface circuits. Any number ofbattery interface circuits may be employed.

The circuitry and control methodology described herein is equallyapplicable to use of modular energy supply systems in automobiles. Forinstance, the control methodology described herein may be used inconnection with Lithium ion batteries used in an automobile. In thisway, the batteries may be removed from the automobile and recharged at aservice station and then replaced into the vehicle fully charged. Thebatteries may be separately removed from the automobile or they may beremoved in groups. The invention as taught and described herein enablethe evaluation of individual batteries and the evaluation of the energyremaining in the batteries at the time they are swapped out (exchanged)for fully charged batteries. In this way a motorist can effectivelyrefuel his or her vehicle and proceed on his or her way without worryingabout stopping to charge the batteries which is time consuming as therecharge time for Lithium ion batteries is considerable. Having theability to quickly swap the batteries in a Lithium ion car enables thedriver to get credit for the energy in his “gas” tank. In reality theteachings of the instant invention enable the driver to effectively havean “energy tank” as compared to a “gas tank.”

FIG. 31 illustrates 3100 exemplary AC input and AC/DC converter circuitswhich are described elsewhere hereinabove in connection with FIGS. 4,4A, 4B, 4C and 5. Reference numeral 3101 indicates input terminals forAC line, neutral, and ground. Reference numeral 3102 indicates an ACinput fuse which protects converter 406. Reference numeral 3103 is an ACinput transient voltage suppression circuit protecting converter 406.Reference numeral 3104 is an indication of an AC detect circuit, asdescribed elsewhere referring to FIG. 4, reference numerals 404, 405.Reference numeral 3105 indicates in an exemplary fashion AC/DCconverter, as described elsewhere referring to FIG. 4, reference numeral406. Reference numeral 3106 is exemplary of AC/DC temperature sensingcircuit, as described elsewhere referring to FIG. 4, reference numeral412E. Reference numeral 3107 indicates AC/DC converter DC output voltageselective coupling as described elsewhere referring to FIG. 4 (referencenumerals 406A and 412).

FIG. 32 illustrates 3200 exemplary AC/DC converter DC output voltage busconnection switches. Selective coupling circuits 3201 are illustratedfor AC/DC to DC INT BUS, as described elsewhere referring to FIG. 4(reference numerals 406A, 407, 423, and 412B). Selective couplingcircuits 3202 for coupling the AC/DC to SECOND DC BUS as set forth andpreviously described in connection with FIG. 4 (406A, 408, 410, and412A). And, selective coupling circuits 3203 for coupling the AC/DC toTHIRD DC BUS, as described elsewhere referring to FIG. 4 (referencenumerals 406A, 409, 411, and 412C).

FIG. 33 illustrates 3300 First DC input circuits wherein referencenumeral 3301 indicates DC input terminals for positive, negative, andground and reference numeral 3302 DC indicates an input fuse. DC inputtransient voltage suppression circuit 3303 is illustrated as an MOV. DCinput voltage monitoring selective coupling circuit 3304 is illustratedand was described elsewhere referring to FIG. 4A (reference numeral438).

FIG. 34 illustrates 3400 the First DC input bus connections switches inexemplary fashion and as described elsewhere referring to FIG. 4A.Selective coupling circuits 3401 for coupling first DC input to secondDC bus (FIG. 4A, reference numerals 430A, 432A, 436, 412A) areillustrated in FIG. 34 as are the selective coupling circuits 3402 forcoupling the first DC input to third DC bus (FIG. 4A, reference numerals430A, 433, 437, 412C). FIG. 34 also depicts selective coupling circuits3403 for the first DC input to DC INT bus as described above inconnection with FIG. 4A, reference numerals 430A, 431, 434, 412B.

Selective coupling circuits 3404 for coupling the first DC input to thefirst DC bus are illustrated in FIG. 34 and also as described above inconnection with FIG. 4A, reference numerals 430A, 432, 435, 412J.

FIG. 35 illustrates 3500 the Second DC input circuits wherein referencenumeral 3501 DC indicates the input terminals for positive, negative,and ground and reference numeral 3502 indicates the DC input fuse.Reference numeral 3503 indicates the DC input transient voltagesuppression circuit (MOV) and reference numeral 3504 illustrates the DCinput voltage monitoring selective coupling circuit as described abovereferring to FIG. 4A, reference numeral 448.

FIG. 36 illustrates 3600 exemplary Second DC input bus connectionswitches, as described above referring to FIG. 4A. Selective couplingcircuits 3601 for coupling the second DC input to second DC bus areillustrated in FIG. 36 and have been described previously in FIG. 4A,reference numerals 439A, 442, 446, 412A. Selective coupling circuits3602 for coupling second DC input to third DC bus are illustrated inFIG. 36 in exemplary fashion and are discussed above in connection withFIG. 4A, reference numerals 439A, 443, 447, 412C. Selective couplingcircuits 3603 for coupling the second DC input to DC INT bus areillustrated by way of example in FIG. 36 and were discussed above inconnection with FIG. 4A, reference numerals 439A, 440, 444, 412B. And,selective coupling circuits 3604 for coupling the second DC input to thefirst DC bus are illustrated by way of example in FIG. 36 and arediscussed above in connection with FIG. 4A, reference numerals 439A,441, 445, 412J.

FIG. 37 illustrates 3700 the Third DC input battery pack array circuitswherein reference numeral 3701 indicates DC input fuse and referencenumeral 3702 indicates DC input transient voltage suppression circuit asdescribed above as an MOV. DC input voltage monitoring selectivecoupling circuit 3703 is also depicted in FIG. 37 and is describedelsewhere described elsewhere in FIG. 4A, reference numeral 459.

FIG. 38 illustrates 3800 the Third DC input bus connections switchesdescribed above in connection with FIG. 4A wherein selective couplingcircuits 3801 couple the third DC input with the second DC bus, FIG. 4A,reference numerals 450B, 453, 457, 412A. Also shown in FIG. 38 are theselective coupling circuits 3802 for coupling the third DC input tothird DC bus as described above in connection with FIG. 4A, referencenumerals 450B, 454, 458, 412C. Selective coupling circuits 3803 forcoupling the third DC input to DC INT bus as described above inconnection with FIG. 4A, reference numerals 450B, 451, 455, 412B andselective coupling circuits 3804 for coupling the third DC input tofirst DC bus are shown in FIG. 38 and were previously described above inconnection with FIG. 4A, reference numerals 450B, 452, 456, 412J.

FIG. 39 illustrates 3900 the First DC/DC converter circuits 3901described above in FIG. 4B (reference numeral 475) wherein First DC/DCconverter temperature measuring circuit 3902 was described in FIG. 4B inconnection with reference numeral 482E. Alternative first DC/DCconverter 3903 having a detailed pin assignment differing from 3901 isalso illustrated in FIG. 39. DC/DC converter voltage monitoringselective coupling circuit 3904 described in connection with FIG. 4B,reference numeral 482 and is illustrated in FIG. 39.

FIG. 40 illustrates 4000 the First DC/DC converter bus connectionsswitches described in connection with FIG. 4B wherein selective couplingcircuits 4001 for coupling the first DC/DC converter to DC INT bus weredescribed in connection with reference numerals 475A, 477, 480, 412B.Selective coupling circuits 4002 for coupling the first DC/DC converterto third DC bus are illustrated in FIG. 40 and were described above inconnection with FIG. 4B, and in particular with reference numerals 475A,478, 480A, 412C. Selective coupling circuits for 4003 for coupling thefirst DC/DC converter to the DC charge bus are illustrated in FIG. 40and were described above in connection with FIG. 4B, reference numerals475A, 479, 481, 489A.

FIG. 41 illustrates 4100 the Second DC/DC converter circuits 4101described elsewhere referring to FIG. 4B (reference numeral 483) and theSecond DC/DC converter temperature measuring circuit 4102 as describedelsewhere referring to FIG. 4B (reference numeral 490E). Alternativesecond DC/DC converter 4103 having a detailed pin assignment differingfrom 4101 is illustrated in FIG. 41 as well. DC/DC converter voltagemonitoring selective coupling circuit 4104 as described elsewherereferring to FIG. 4B (reference numeral 490) is also illustrated in FIG.41.

FIG. 42 illustrates 4200 in exemplary fashion the Second DC/DC converterbus connections switches described in FIG. 4B wherein the selectivecoupling circuits 4201 for coupling the second DC/DC converter to DC INTbus. See the discussion of FIG. 4B as it pertains to reference numerals483A, 484, 487, 412B. Selective coupling circuits 4202 for coupling thesecond C/DC converter to third DC bus as described in above inconnection FIG. 4B and reference numerals 483A, 485, 488, 412C are shownin FIG. 42. Also, selective coupling circuits 4203 for coupling thesecond DC/DC converter to DC charge bus are shown in FIG. 42 and werediscussed above in connection with FIG. 4B, reference numerals 483A,486, 489, 489A.

FIG. 43 illustrates 4300 the DC/AC inverter circuits wherein the DC/ACinverter input power switch 4301 as described elsewhere referring toFIG. 4, reference numeral 413, and DC/AC inverter 4302 as described inFIG. 4, reference numeral 414 are shown. DC/AC inverter temperaturemeasuring circuit 4303 is also illustrated in FIG. 43 and previouslydescribed referring to FIG. 4, reference numeral 416B.

Still referring to FIG. 43, DC/AC inverter output terminals 4303 forline, neutral, and ground are shown as is the DC/AC inverter output fuse4305. DC/AC inverter output transient voltage suppression circuit 4306is illustrated in FIG. 43 as an MOV and was described previously. DC/ACinverter AC detect circuit 4307 is illustrated in FIG. 43 and wasdescribed above in regard to FIG. 4, reference numeral 415 and 416.

FIG. 44 illustrates 4400 the First DC output circuits wherein the FirstDC output switch 4401 was described elsewhere referring to FIG. 4,reference numeral 425. First DC output terminals 4402 for positive,neutral, and ground are shown in FIG. 44 as is the First DC output fuse4403. First DC output transient voltage suppression circuit 4404 is anMOV as was previously described above. First DC output voltagemonitoring selective coupling circuit 4405 is illustrated in FIG. 4 anddescribed above in connection with FIG. 4, reference numeral 420. DC/ACinverter input voltage monitoring selective coupling circuit 4406 isalso illustrated in FIG. 44 and was described hereinabove in connectionwith FIG. 4, reference numeral 419.

FIG. 45 illustrates 4500 the Third DC bus and fourth DC/DC convertercircuits wherein the Third DC bus voltage monitoring selective couplingcircuit 4501 as described elsewhere referring to FIG. 4A, referencenumeral 470A. Fourth DC/DC converter input voltage switch 4502 isdisclosed in FIG. 45 as described elsewhere referring to FIG. 4A,reference numeral 474. Fourth DC/DC converter output voltage monitoringselective coupling circuit 4503 as described elsewhere referring to FIG.4A, reference numeral 473A.

FIG. 46 illustrates 4600 the fourth, fifth, and sixth DC outputs andfourth DC/DC converter circuits wherein the Fourth DC output terminalsfor positive, neutral, and ground 4601 and the Fourth DC output fuse4602 are illustrated. The Fourth DC output transient voltage suppressioncircuit 4603 is an MOV and the Fifth DC output terminals 4604 forpositive, neutral, and ground are also illustrated in FIG. 46. Fifth DCoutput fuse 4605 and the Fifth DC output transient voltage suppressioncircuit 4606 which is an MOV are illustrated in FIG. 46. Fourth DC/DCconverter 4607 and Sixth DC output 4608 as described elsewhere referringto FIG. 4A, reference numeral 473 and 472, respectively, are alsoillustrated in FIG. 46. And, Fourth DC/DC converter temperaturemeasuring circuit 4609 is illustrated in FIG. 46 and was illustratedpreviously in FIG. 4A as reference numeral 473E.

FIG. 47 illustrates 4700 serial to parallel circuits to implement serialmicroprocessor control instructions into parallel control signalswherein power supply decoupling capacitors 4701 for the respectiveintegrated circuits are shown. Serial to parallel converters 4702 arealso illustrated in FIG. 47.

FIGS. 48-50, reference numerals 4800, 4900, 5000, illustrate additionalserial to parallel circuits implementing the microprocessor controlsignals.

FIG. 51 illustrates 5100 Microcontroller interface circuits wherein thetemperature measuring circuit interface 5101 to the microcontroller isshown and was described elsewhere referring to FIG. 4C, referencenumeral 462. Reference numeral 5102 indicates the battery monitor buscircuit interface to microcontroller as described elsewhere referring toFIG. 5, reference numeral 495A. Reference numeral 5103 indicates avoltage monitor circuit interface to the microcontroller as describedelsewhere referring to FIG. 4C, reference numeral 460. The currentmonitor circuit interface 5104 to the microcontroller is shown in FIG.51 and is described elsewhere referring to FIG. 4C, reference numeral461. And, reference numeral 5105 indicates the serial interface tomicrocontroller as described elsewhere referring to FIG. 4C, referencenumeral 499.

FIG. 52 illustrates 5200 the Microcontroller and support circuits.Reference numeral 5201 indicates the voltage regulator and power supplyfor the microcontroller as described elsewhere referring to FIG. 4C,reference numerals 403, 430A, 439A, 450B, 497A and 497. TheMicrocontroller unit is indicated as reference numeral 5202.

FIG. 53 illustrates 5300 the Microcontroller interface circuits whereindoor switch interface circuit 5301 to the microcontroller is shown andwas described elsewhere referring to FIG. 4C, reference numeral 491.Reference numeral 5302 represents a light emitting diode interfacecircuit to the microcontroller as was described elsewhere referring toFIG. 4C, reference numeral 494. Dual cooling fan control circuitsinterface 5303, 5304 to the microcontroller are shown and were describedelsewhere referring to FIG. 4C (498).

FIG. 54 illustrates 5400 current monitoring circuits in an exemplaryfashion. Reference numeral 5401 indicates the current monitor interfacefor third DC input battery pack array as described elsewhere referringto FIG. 4A, reference numeral 495A. Reference numeral 5402 indicates thecurrent monitor interface for the first DC input as described elsewherereferring to FIG. 4A, reference numeral 438A. Current monitor interface5403 for second DC input is also shown in FIG. 54 and was previouslydescribed above referring to FIG. 4A, reference numeral 448A. Currentmonitor interface 5404 for AC/DC converter output is indicated in FIG.54 as well and was described elsewhere referring to FIG. 4, referencenumeral 412D.

FIG. 55 illustrates 5500 the current monitoring circuits wherein thecurrent monitor interface for the first DC/DC converter 5501 is shownand was described elsewhere referring to FIG. 4B, reference numeral482A. Reference numeral 5502 indicates the current monitor interface forthe second DC/DC converter and was described elsewhere herein in regardto FIG. 4B, reference numeral 490A. Reference numeral 5503 indicatescurrent monitor interface for DC/AC inverter input as was describedelsewhere referring to FIG. 4, reference numeral 416A.

FIG. 56 illustrates 5600 a current monitoring circuits wherein referencenumeral 5601 indicates the current monitor interface for first DC outputas described elsewhere referring to FIG. 4, reference numeral 420A.Current monitor interface 5602 for the second DC output as describedelsewhere referring to FIG. 4 Reference numeral 5603 indicates thecurrent monitor interface for third DC/DC converter as describedelsewhere referring to FIG. 4, reference numeral 424A and referencenumeral 5604 indicates the current monitor interface for fourth DC/DCconverter as described elsewhere referring to FIG. 4A, reference numeral473B.

FIG. 57 illustrates 5700 the DC/DC converter voltage programmingcircuits wherein reference numeral 5701 indicates the voltageprogramming circuit for the first DC/DC converter as described elsewherereferring to FIG. 4B, reference numeral 495X. Voltage programmingcircuit 5702 for the third DC/DC converter is illustrated in FIG. 57 andwas described elsewhere referring to FIG. 4B, reference numeral 495X.Reference numeral 5703 is the voltage programming circuit for the secondDC/DC converter as described elsewhere referring to FIG. 4B, referencenumeral 495X. Reference numeral 5704 indicates the voltage programmingcircuit for the fourth DC/DC converter as described elsewhere referringto FIG. 4B, reference numeral 495X. And, reference numeral 5705indicates the digital to analog converter used to generate voltageprogramming levels.

FIG. 58 illustrates 5800 the second and third DC outputs and third DC/DCconverter circuits in an exemplary fashion wherein the Third DC/DCconverter input voltage switch 5801 is shown and was described elsewherereferring to FIG. 4, reference numeral 425A. The Third DC/DC convertervoltage monitoring selective coupling circuit 5802 is also shown in FIG.58 and was described elsewhere referring to FIG. 4, reference numeral424. Third DC/DC converter 5803 is shown as well in FIG. 58 and wasdescribed elsewhere referring to FIG. 4, reference numeral 427. SecondDC output terminals 5804 are indicated as well for positive, neutral,and ground (426). Also shown is the Second DC output fuse 5805 and theSecond DC output transient voltage suppression circuit 5806 which is an(MOV). Third DC output 5807 (FIG. 4, reference numeral 428). Third DC/DCconverter temperature measuring circuit 5808 is also shown in FIG. 58and was described elsewhere referring to FIG. 4, reference numeral 424B.

FIG. 59A is schematic 5900A illustrating twenty battery packs 5901interconnected in parallel to a common battery bus 5903 leading toeither a DC-AC inverter 5915 of FIG. 59 or to a DC-DC converter 5906 ofFIG. 59B which subsequently is interconnected to a DC-AC inverter 5916.

FIGS. 59B and 59C are schematics 5900B and 5900C illustrating: theinterconnection of the battery array 5901 with a DC-DC converter 5906which is interconnected via cable assembly 5907 with a diode 5912 whichin turn is interconnected with a bus leading to a DC-AC inverter; and,the interconnection via cable assembly to connector 5909 to connector5910 of an AC-DC converter 5908 which in turn is interconnected with adiode which in turn is interconnected with a bus leading to the DC-ACinverter 5915.

FIG. 59D illustrates 5900D the power supply with the battery rack 5924is removed therefrom and the electronics 5921 (AC/DC converter, diodesetc.) mounted to the rear wall 5922 of the housing or frame 5918; alsoshown are two removable Lithium Ion rechargeable battery packs 5926.Electronics 5920 (DC/AC inverters) are also mounted to the rear wall onthe ceiling of the power supply. A grouping of wires (harness) 5925 isalso illustrated.

FIG. 59E is a view 5900E similar to FIG. 59D illustrating the powersupply with the battery rack removed therefrom and further illustratingthe power receptacles 5923, the AC input on the right hand side thereof,and the on-off switch. FIG. 59F is a view similar to FIGS. 59D and 59Ewith the battery rack 5924 mounted in the housing or frame.

FIG. 59G is a view 5900G similar to the immediately preceding FIGS.59D-59F inclusive with the battery rack populated with removablecartridge type Lithium Ion batteries 5926. Also shown is box 5927 withelectronic communications equipment therein representing a load devicebeing powered by the power supply.

FIG. 59H is a view 5900H similar to the immediately preceding FIGS.59D-59G inclusive with the door of the power supply closed andillustrating the power supply interconnected with a load 5927 such aswireless radio equipment.

FIGS. 59A-59H illustrate the example of a power supply having a DC inputfrom a plurality of removable, hot-swappable, and interchangeable powerbatteries 5901 which provide power on a common battery bus 5903 to aDC-AC inverter 5915. Alternatively, and additionally, AC power may besupplied to the power supply through an AC-DC converter 5908 which isthen converted back to AC by inverter 5915 outputting to 5916 forpurposes of reliability and for the purpose of seamless transition(on-line topology). The output of the AC to DC converter is arranged ina diode oring fashion together with the output from the common batterybus 5903 via diodes 5912. The diode oring selects of the higher voltagein converting from DC to AC power. Further, the common battery busvoltage may be converted by a DC to DC converter 5906 intermediate thecommon battery bus 5903 and the diode 5912 in series leading to thejunction with the output of the AC-DC converter. Use of the DC to DCconverter is optional depending on the voltage of the batteries used inthe power supply and thus enables use of rechargeable batteries whichhave a relatively low output voltage. In the example of FIGS. 59A-59G apower supply is provided which does not require a microprocessor tomanage its operations. Rather, this example provides a seamlesstransition from an AC power input to a DC power input withhot-swappability of the batteries. The batteries may be cordless toolbatteries capable of dual use. Further, the batteries may be Li-Ion orany of the types referred to herein.

FIG. 60 is an illustration of the conceptual management hierarchy of thepower supply system. By virtue of this hierarchical arrangement thenetwork management user may access the status and control parameters forall subsystems under a particular gateway. This is described elsewherereferring to FIGS. 9A and 9B. In particular, in FIG. 9B, information isshown for batteries (energy subsystems and energy modules of FIG. 60),inputs, converters, and outputs (power conversion and control units ofFIG. 60), and SIPS IP ADDR (gateway of FIG. 60).

Reference numeral 6001 is the Gateway which interconnects the powersupply system below to a network (local or wide area). All aspects ofthe underlying power supply status and operation may be monitored andcontrolled by the user via this network. Reference numeral 6002 is usedto indicate in exemplary fashion that up to P (where P is a positiveinteger) power conversion and control units may be connected formanagement purposes to each gateway. Similarly, reference numeral 6003indicates in exemplary fashion that up to S energy subsystems (where Sis a positive integer) may be connected for management purposes to eachpower conversion and control unit. Reference numerals 6004 indicatesthat up to M energy modules (where M is a positive integer) may beconnected for management purposes to each energy subsystem. Energymodules include but are not limited to lithium ion based batteries.

FIG. 61A is an exemplary depiction of the physical arrangement of apower supply system. By virtue of this hierarchical arrangement thepower supply user may configure and control a power supply systems undera particular gateway. In particular FIG. 61 shows an example of aphysical arrangement of a gateway unit 6101 connected to at least onepower conversion and control unit 6102 which in turn is connected to atleast one energy subsystem 6103 which in turn is connected to at leastone energy module 6104. In particular, in FIG. 61, the power conversionand control unit is depicted as physically separate from the energysubsystems. Further the energy subsystems are shown to house the energymodules. As long as at least one energy subsystem having at least oneenergy module is connected to a power conversion and control unit, thepower conversion and control unit may continue to operate provide powerand management control to the user.

FIG. 61B is an alternative depiction of a physical arrangement of apower supply system. In this case the gateway, power conversion andcontrol unit, energy subsystem, and energy modules are co-housed in acommon enclosure 6105. Electrical interconnections are otherwiseequivalent with the arrangement of FIG. 61A. Additionally, an energysubsystem 6103 (separately housed) is shown connected to the powerconversion and control unit housed within 6105. Additional externalenergy subsystems may be connected at the same time. As mentionedearlier, as long as at least one energy subsystem (co-housed orseparately housed) having at least one energy module is connected to apower conversion and control unit, said power conversion and controlunit may continue to operate provide power and management control to theuser.

Just as the instant invention contemplates that various functional unitsmay be packaged separately or coincidently, so does the invention alsocontemplate that control may be implemented in a single microcontrolleror distributed across multiple intercommunicating microcontrollers. Inone example, each gateway may have a microcontroller, each powerconversion and control unit may have a microcontroller, each energysubsystem may have a microcontroller, each of the microcontrollersintercommunicating with others to which it is connected for thatpurpose. In another example, a single microcontroller may control allunits including gateway, multiple PCCU's, etc.

The battery power supply circuitry and control methodology describedherein is equally applicable to modular energy systems for batteryelectric vehicles of types including but not limited to automobiles,ultra light weight automobiles, scooters, motorized bicycles andtricycles, buses, trucks, military vehicles, boats, etc. For instance,the control methodology described herein may be used in connection withlithium ion batteries in an electric automobile. Referring to FIG. 62, apower supply 6201 using quick disconnect cartridge type batteries 6202within an automobile 6203 connects any combination of batteries viaswitches 508 to a battery bus 450A which in turn connects battery powerto the vehicle electric motor system to power motors 6204. The powersupply 6201 can also receive power regenerated by braking during vehicleoperation from the vehicle motor control system and can connect saidreceived power to the charge bus 489A which in turn routes power viaswitches 512 to batteries for re-charging. At an appropriatelyconfigured service station 6205, the automobile's partially dischargedbatteries 6202 may be quickly removed and replaced with fully chargedbatteries 6206 from the service station. The batteries 6202 may beenergy modules or hand sized battery packs such as 6104 or they may beenergy subsystems including multiple energy modules such as 6103.Removal and replacement at the service station may proceed at the module6104 or subsystem 6103 level. Repair or replacement of failed modules isstill possible at the module 6104 level.

Removed battery modules or subsystems may be recharged outside of thevehicle by a service station power supply using the control mechanismsdescribed in conjunction with the charge bus 489A from FIGS. 4 and 5 andswitches 512. The invention as taught and described herein enablesvarious evaluations of individual batteries including the estimation ofthe energy remaining in the batteries at any time including the time atwhich they are being removed from a vehicle. This evaluation isfacilitated using the battery monitor bus 495A and the battery info bus495B along with the calculations performed by microcontroller 495. Thecondition of individual batteries is also estimated including remainingcycle life (how many more time a battery may be charged and dischargedbefore end of life), present capacity (how much energy the battery canhold in its current state of health), internal resistance or impedance,and maximum current or power capability. Batteries may be likewiseevaluated at the time they are being installed into a vehicle. Eitherthe vehicle born system or the service station system or both mayperform these evaluations. In this way the battery power supply vehiclesystem can calculate a “refueling” fee to be paid by the motorist whichcorresponds appropriately to the net gain in energy (i.e. energy of thereplacement batteries less energy of removed batteries) as well as anyfee components, surcharges, or credits corresponding to the differentiallife or other conditions of the replacement versus the removedbatteries. As mentioned above, batteries removed from vehicles arere-charged external to the vehicle at the service station after themotorist continues on his way with his charge laden replacementbatteries. In this way the motorist can effectively “refuel” his or hervehicle and proceed on his or her way quickly, in a time framecomparable to the gasoline refueling process, for a fair fee based onthe actual energy gained in refueling, without worrying about thesignificant recharge time for lithium ion or other battery types thatwould otherwise require inconvenient delays if the batteries needed tobe recharged in place aboard the vehicle.

Since many batteries are processed (evaluated, recharged, andmaintained) external to vehicles at appropriate service stations, thestation can be configured to optimize the recharging and other handlingprocedures associated with its array of batteries. For example,batteries can be charged at a moderate rate that is optimized formaximizing battery life, or at a rate or time of day that is optimal forminimizing recharge energy cost, or other cost factors. For example,electrical demand costs can be controlled by controlling in turn whichbatteries are connected to the charge bus at any given time. In otherwords, batteries may be charged at night when the availability of poweris high and the demand costs are low. In this way, refueling of anelectric vehicle using quick disconnect batteries or groups of batteriesis most cost effective. Additionally, use of the electric utility gridto charge batteries at a service station for insertion into a vehicle torefuel it effectively enables energy to be supplied to a vehicle throughbatteries charged with power made from coal, natural gas, atomic energy,wind or solar panels. This optimization is not as feasible if thebatteries remain in the vehicle to be recharged while the motoristwaits. Under such conditions the motorist's convenience becomes thelimiting factor.

It is also an aspect of the present invention that the batteries may berecharged while remaining in the vehicle such that, when recharge timeis not a limiting factor such as when the vehicle is not in use, andwhen a satisfactory electrical power source is available such as anelectric utility outlet, “refueling” can occur without the need of abattery exchange at a battery service station. The invention disclosedherein allows the charge bus and related control and switchingmechanisms to operate to the effect of the desired recharging while thebatteries remain aboard the vehicle.

It is also an aspect of the present invention that auxiliary vehiclebatteries may be held by the motorist, either at the vehicle's home ordepot site, or carried aboard the vehicle as additional payload, saidauxiliary batteries being interchangeable with the operating batteriesof the vehicle in relatively efficient fashion so that the vehicle maybe “refueled” by the motorist by exchanging spent batteries with chargedauxiliary batteries. Spent batteries may then be delivered to a batteryservice station for credit, recharging, or exchanged for chargedbatteries, or may be recharged external to or onboard the vehicle by themotorist himself or other party.

The invention described herein has been set forth by way of exampleonly. Those skilled in the art will readily recognize that changes maybe made to the invention without departing from the spirit and scope ofthe invention as defined by the claims which are set forth below.

1. A rack for housing a plurality of removable batteries comprising atleast one shelf, each of said batteries includes a first electricalbattery contact and a second electrical battery contact, said shelfincludes at least one docking location, said docking location includes afirst electrical battery connector which matingly engages said firstelectrical battery and a second electrical battery connector whichmatingly engages said second electrical battery contact, and, first andsecond electrical battery conductors affixed to each of said first andsecond electrical battery connectors.
 2. A rack for housing a pluralityof removable batteries as claimed in claim 1 wherein said removablebatteries are quick-disconnect, cartridge type batteries.
 3. A rack forhousing a plurality of removable batteries as claimed in claim 1 whereinsaid removable batteries are Li-ion batteries.
 4. A rack for housing aplurality of removable batteries as claimed in claim 1 wherein saidremovable batteries are cordless tool batteries.
 5. A rack for housing aplurality of removable batteries as claimed in claim 1 furthercomprising at least one battery interface circuit.
 6. A rack for housinga plurality of removable batteries as claimed in claim 5 wherein saidfirst and second electrical battery conductors are in communication withsaid battery interface circuit.
 7. A rack for housing a plurality ofremovable batteries as claimed in claim 6 wherein said battery interfacecircuit comprises at least one electrical connector for connecting to amotherboard.
 8. A rack for housing a plurality of removable batteries asclaimed in claim 1 further comprising mechanical fasteners forattachment to a supporting structure.
 9. A rack for housing a pluralityof removable batteries as claimed in claim 1, wherein said dockinglocation is adapted to mechanically interlock with said removablebattery.
 10. An enclosure for housing at least one battery rack, saidbattery rack having a plurality of batteries.
 11. An enclosure forhousing at least one battery rack as claimed in claim 10, said enclosurefurther comprising mechanical fasteners interengaging said battery rack.12. An enclosure for housing at least one battery rack as claimed inclaim 10, said enclosure further comprising mechanical fasteners forsecuring a motherboard.
 13. An enclosure for housing at least onebattery rack as claimed in claim 12, said motherboard having at leastone electrical connector for connecting to said battery rack.
 14. Anenclosure for housing at least one battery rack as claimed in claim 10,further comprising at least one power input and at least one electricalconnector for connecting to a power source.
 15. An enclosure for housingat least one battery rack as claimed in claim 10, further comprising atleast one power output and at least one electrical connector forconnecting said power output to an electrical load.
 16. An enclosure forhousing at least one battery rack as claimed in claim 10 having at leastone hand hold affixed so as to be easily lifted and carried.
 17. Anenclosure for housing at least one battery rack as claimed in claim 10,further comprising at least one power output and at least onequick-disconnect type electrical connector for connecting said poweroutput to an electrical vehicle, further comprising a quick-disconnecttype mechanical connector for connecting said enclosure to said electricvehicle.
 18. An enclosure for housing at least one battery rack asclaimed in claim 10, said enclosure further comprising at least onepower input and at least one quick-disconnect type electrical connectorfor connecting said power input to an electric vehicle service station,said enclosure further comprising a quick-disconnect type mechanicalconnector for connecting said enclosure to said electric vehicle servicestation.
 19. An enclosure for housing at least one battery rack, saidbattery rack having a plurality of batteries, comprising at least onepower output and at least one quick-disconnect type electrical connectorwhich couples said power output to an electric vehicle, aquick-disconnect type mechanical connector which couples said enclosureto said electric vehicle and, wherein said at least one power output andsaid electrical connector couples to a power source at an electricvehicle station, and wherein said quick disconnect type mechanicalconnector couples said enclosure to said electric vehicle station. 20.An enclosure for housing at least one battery rack, said battery rackcomprising a plurality of batteries as claimed in claim 19, furthercomprising a transfer apparatus which mechanically couples to said quickdisconnect type mechanical connector to move said enclosure from saidelectric vehicle to said electric vehicle station and vice-versa.